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Full text of "NB NBIC 3 (2007): 2009 Addendum to Part 3"

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NOTICE OF INCORPORATION 

United States Legal Document 

J^" All citizens and residents are hereby advised that 
this is a legally binding document duly incorporated by 
reference and that failure to comply with such 
requirements as hereby detailed within may subject you 
to criminal or civil penalties under the law. Ignorance of 
the law shall not excuse noncompliance and it is the 
responsibility of the citizens to inform themselves as to 
the laws that are enacted in the United States of America 
and in the states and cities contained therein. "^& 

* * 

NBIC 2007, National Board Inspection Code, 
Part 3, Repair and Alteration, 2009 Addenda, 
as mandated by the requirements of the States 
of Alabama, Alaska, Arizona, Colorado, Iowa, 
Kansas, Michigan, Missouri, Nebraska, New Jersey, 
North Dakota, Ohio, Oregon, and Utah. 






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The 
National 

BOARD 

□ f boiler and 
Pressure Vessel 
Inspectors 




W Sill 111 I II ml 

Board 

nspecnop 

Code 



Part 3 - Repairs and Alterations 



NATIONAL BOARD INSPECTION CODE 



NOTE: Pages ii through xvi are not part of this 
American National Standard. 



Library of Congress Catalog Card No. 52-44738 

Printed in the United States of America 

All Rights Reserved 

©2009 
The National Board of Boiler and Pressure Vessel Inspectors 

Headquarters 

1 055 Crupper Avenue 

Columbus, Ohio 43229-1 1 83 

614.888.8320 

614.847.1828 Fax 

Testing Laboratory 

7437 Pingue Drive 

Worthington, Ohio 43085-1 71 5 

614.888.8320 

614.848.3474 Fax 

Training & Conference Center 

1065 Crupper Avenue 

Columbus, Ohio 43229-1 1 83 

614.888.8320 

614.847.5542 Fax 

inspection Training Center 

1 075 Crupper Avenue 

Columbus, Ohio 43229-1 183 

614.888.8320 

614.431.3208 Fax 



NATIONAL BOARD INSPECTION CODE 

The National Board of Boi!er and Pressure Vessel Inspectors 
Board of Trustees 

R.J. Abenjr. 
Chairman 

J.T. Amato 
First Vice Chairman 

D.J. Jenkins 
Second Vice Chairman 

D.A. Douin 

Secretary/Treasurer 

J.M. Given Jr. 
Member at Large 

G.L. Scribner 
Member at Large 

D.C. Price 

Member at Large 

B. Krasiun 
Member at Large 



Advisory Committee 

G. W. Galanes, P.E. 
representing welding industries 

E.J. Hoveke 
representing National Board certificate holders 

L.J. McManamon Jr. 
representing organized labor 

M.J. Pischke 
representing pressure vessel manufacturers 

B.R. Morelock, P.E. 
representing boiler and pressure vessel users 

C.E. Perry 
representing boiler manufacturers 

C.G. Schaber 
representing authorized inspection agencies (insurance companies) 



NATIONAL BOARD INSPECTION CODE 



National Board Members 

Alabama Ralph P. Pate 

Alaska Chris Fulton 

Arizona Randall D.Austin 

Arkansas Gary R. Myrick 

California Donald C. Cook 

Colorado Steve Nelson 

Connecticut 

Delaware James B. Harlan 

Florida Michael A. Bums 

Georgia Paul J. Welch 

Hawaii Keith A. Rudolph 

Idaho MikePoulin 

Illinois BennieF. Bailey 

Indiana Dan Willis 

l° wa Michael Klosterman 

Kansas ; Donald J. Jenkins 

Kentucky Rodney Handy 

Louisiana William Owens 

Maine John H. Burpee 

Maryland Karl J. Kraft 

Massachusetts Edward S. Kawajr. 

Michigan Robert J. Aben Jr. 

Minnesota Joel X Amato 

Mississippi Kenneth L.Watson 

Missouri Gary L. Scribner 

Montana Timothy Stewart 

Nebraska Christopher B. Cantrel I 

Nevada R 0y L. Perry 

New Hampshire Wayne Brigham 

New Jersey Milton Washington 

New York Peter L Vescio Jr. 

North Carolina JackM. Given Jr. 

North Dakota Robert Reetz 

Ohio DeanT. Jagger 

Oklahoma Tom Monroe 

Oregon Michael D. Graham 

Pennsylvania Jack A. Davenport 

Rhode Island Benjamin Anthony 

South Carolina Ronald W. Spiker 

South Dakota Howard D. Pfaff 

Tennessee Audrey E. Rogers 

Texas Anthony P.Jones 

Utah Rick K.Sturm 

Vermont Wesley E. Crider Jr. 

Virginia Edward G. Hilton 

Washington Linda Williamson 

West Virginia John F. Porcella 

Wisconsin Michael J. Verhagen 

Chicago, IL Michael J. Ryan 

Detroit, Ml John E. Bell 

Los Angeles, CA JovieAclaro 

Milwaukee, Wl Randal S. Pucek 

New York, NY William McGivney 

Alberta Ken K.T Lau 

British Columbia John G. Siggers 

Manitoba Terry W. Rieger 

New Brunswick Dale E. Ross 

Newfoundland & Labrador E. Dennis Eastman 

Northwest Territories Steve Donovan 

Nova Scotia ' Peter Dodge 

Nunavut Territory 

Ontario Gilles Lemay 

Prince Edward Island Kenneth Hynes 

Quebec Madiha M. Kotb 

Saskatchewan Brian Krasiun 

Yukon Territory Daniel C. Price 



NATIONAL BOARD INSPECTION CODE 



National Board Inspection Code Committees 



Main Committee 



T. Parks, Chair 

The National Board of Boiler and 

Pressure Vessel Inspectors 


J. Pillow 

Common Arc Corporation 


R. Wielgoszinski, Vice Chair 
Hartford Steam Boiler Inspection and 
Insurance Company of Connecticut 


R. Reetz 

State of North Dakota 


R. Hough, Secretary 

The National Board of Boiler and 

Pressure Vessel Inspectors 


H. Richards 
Southern Company 


S. Bacon 

Conoco Phillips-Ferndale Refinery 


J. Richardson 
Consultant-Dresser, Inc. 


P. Bourgeois 
Travelers 


G. Scribner 
5tate of Missouri 


D. Canonico 
Canonico & Associates 


J. Sekely 

Wayne Crouse Inc. 


D. Cook 

Stare of California 


R. Snyder 
ARISE, Inc. 


P. Edwards 

Stone & Webster, Inc. 


S. Staniszewski 

US Department of Transportation 


G. Galanes 

Midwest Generation EME, LLC 


R. Sulzer 

The Babcock & W7/cox Company 


J. Given 

State of North Carolina 


H. Titer 

MIRANT Mid-Atlantic 


F. Hart 

Furmanite Corporation 


J. Yagen 
Dynegy, Inc. 


C. Hopkins 
Seattle Boiler Works 




D. Parrish 
FM Global 





NATIONAL BDARD INSPECTION CODE 



Subcommittee for Installation (Part 1) 



H. Richards, Chair 
Southern Company 




H.Tyndall 

Zurich Services Corp. 


C. Hopkins 
Seattle Boiler Works 




C. Scribner 
State of Missouri 


P. Bourgeois 
Travelers 




R. Snyder 
ARISE, Inc. 


G. Halley 
ABMA 




R. Sulzer 

The Babcock & Wilcox Company 


S. Konopacki 
Midwest Generation 




H. Titer 

MIRANT Mid-Atlantic 


B. Moore 

Hartford Steam Boiler Inspection and 

Insurance Company of Connecticut 


J. Yagen 
Dynegy, Inc. 



Subgroup for Installation (Part 1) 



Boilers 




Pressure Vessels and Piping 


C. Hopkins, Chair 
Seattle Boiler Works 




J. Yagen, Chair 
Dynegy, Inc. 


P. Bourgeois 
St. Paul Travelers 




H. Richards 
Southern Company 


G. Halley, P.E. 
ABMA 




G. Scribner 
State of Missouri 


S. Konopacki 
Midwest Generation 




R. Snyder 
ARISE, Inc. 


B. Moore, P.E. 
Hartford Steam Boiler 


Inspection 


H. Titer 

MIRANT Mid-Atlantic 


H.Tyndall 

Zurich Services Corp. 




H.Tyndall 

Zurich Services Corp. 


G. Scribner 
State of Missouri 






R. Sulzer 

The Babcock & Wilcox 


Company 





VI 



NATIONAL BOARD INSPECTION CODE 



Subcommittee for Inspection (Part 2) 



D. Cook, Chair 
State of California 


D. Parrish 
FM Global 


S. Bacon 

Conoco Phillips-Ferndale Refinery 


R. Reetz 

State of North Dakota 


D. Canonico 
Canonico & Associates 


J. Richardson 
Consultant-Dresser, Inc. 


J. Getter 
Worthington Cylinders 


J. Riley 

Chevron Energy and Technology 


G. McRae 

Trinity Industries, Inc. 


M. Schwartzwalder 
AEP 


V. Newton 
Chubb & Son 


S. Staniszewski 

US Department of Transportation 


T. Barker 
FM Global 


R. Wacker 
Dupont 


M. Horbaczewski 
Midwest Generation 


M. Mooney 

Liberty Mutual Insurance 



Subgroup for Inspection 


(Part 2) 




General Requirements 




Specific Requirements 


J. Getter, Chair 
Worthington Cylinders 




S. Staniszewski 

US Department of Transportation 


D. Canonico 
Canonico & Associates 




S. Bacon 

Conoco Phillips-Ferndale Refinery 


R. Dobbins 
Zurich N.A. 




D. Cook 

State of California 


M. Horbaczewski 
Midwest Generation 




R. Dobbins 
Zurich N.A. 


D. Parrish 
FM Global 




J. Getter 
Worthington Cylinders 


J. Richardson 
Consultant-Dresser, Inc. 




G. McRae 

Trinity Industries, Inc. 

J. Riley 

Chevron Energy and Technology 

M. Schwartzwalder 
AEP 

R. Wacker 
Dupont 



VII 



NATIONAL BDARD INSPECTION CODE 



Subcommittee for Repairs and Alterations (Fart 3) 



C. Galanes, Chair 

Midwest Generation EME, LLC 

P. Edwards 

Stone & Webster, Inc. 

J. Given 

State of North Carolina 

Wayne Jones 
Arise, Inc. 

J. Larson 

OneBeacon America Insurance Company 



F. Pavlovicz 

The Babcock & Wilcox Company 

J. Pillow -Vice Chair 
Common Arc Corporation 

B. Schulte 
NRG Texas, LP 

J. Sekely 

Wayne Crouse Inc. 

M. Webb 
Xcel Energy 



Subgroup for Repairs and Alterations (Part 3) 



General Requirements 

P. Edwards, Chair 
Stone & Webster, Inc. 

J. Larson 

One Beacon America Insurance Company 

R. Pulliam 

The Babcock & Wilcox Company 

B. Schulte 
NRG Texas, LP 

M. Webb 
Xcel Energy 

B. Boseo 

Alstom/AP ComPower Inc. 

Brian Morelock 
Eastman Chemical 



Specific Requirements 

J. Sekely 

Wayne Crouse Inc. 

G. Galanes 

Midwest Generation EME, LLC 

j. Given 

State of North Carolina 

W. Jones 
ARISE, Inc. 

F. Pavlovicz 

The Babcock & Wilcox Company 

J. Pillow, Chair 
Common Arc Corporation 

B. Boseo 

Alstom/AP ComPower Inc. 

Michael Huffman 
American Welding & Tank 



VIII 



NATIONAL BOARD INSPECTION CODE 



Subcommittee for Pressure Relief Devices (Parts 1, 2, and 3) 


F. Hart, Chair 
Furmanite America Inc. 


R. Donalson 

Tyco Valves and Controls 


A. Cox 
Industrial Value 


K. Fitzsimmons 
Carter Chambers, LLC 


J. Ball 

The National Board of Boiler and 

Pressure Vessel Inspectors 


G. Humphries 
Oxy Vinyls, LP 


M. Brodeur 

International Valve & Instr. Corp. 


R. McCaffrey 
Quality Valve 


S. Cammeresi 
CCR 


T. Pate I 

Farris Engineering 


D. DeMichael 
DuPont 





Special Subgroups for Installation, Inspection, and Repairs and Alterations (Parts 1, 2, and 3) 



Locomotive Boilers 




B. Withuhn, Chair 
Smithsonian Institution 


S. Lee 

Union Pacific Railroad 


S. Butler 

Midwest Locomotive & Machine 

Works 


D. McCormack 
Consultant 


D. Conrad 

Valley Railroad Co. 


L. Moedinger 
Strasburg Railroad 


R. Franzen 

Steam Services of America 


R. Reetz 

State of North Dakota 


D. Criner 

Wasatch Railroad Contractors 


G. Scerbo 

Federal Railroad Administration 


S. Jackson 
D&SNC 


R. Schueler 

The National Board of Boiler and Pres- 
sure Vessel Inspectors 


M. Janssen 

Vapor Locomotive Company 


R. Stone 

ABB/Combustion Engineering 




R.Yuill 
Consultant 



Historical Boilers 



R. Reetz, Chair 
State of North Dakota 


D. Cook 

State of California 


T. Dillion 
Deltak 


B. Babcock 
Consultant 


M. Wahl 
WHSEA 


D. Rupert 
Consultant 


J. Larson 

One Beacon America 

Company 


S. Bacon 
Insurance Conoco Phillips-Ferndale Refinery 


F. Johnson 
PCS Phosphate 





IX 



NATIONAL BOARD INSPECTION CDDE 



Special Subgroups for Installation, Inspection, and Repairs and Alterations (Parts 1, 2, and 3) 



Graphite 


Fiber-Reinforced Pressure Vessels 


E. Soltow, Chair 

SGL Carbon Croup/SCL Technic 


B. Shelley, Chair 
DuPont 


W. Banker 
Graphite Repairs, Inc 


F. Brown 

The National Board of Boiler and 

Pressure Vessel Inspectors 


F. Brown 

The National Board of Boiler and 

Pressure Vessel Inspectors 


J. Bustillos 

Bustillos and Consultants 


K. Cummins 
Louisville Graphite 


D. Eisberg 

Energy Recovery Inc. 


S. Malone 
Carbone of America 


T. Fowler 
Retired/Spicewood, TX 


M. Minick 

One CIS Insurance 


D. Keeler 

The Dow Chemical Company 


A. Stupica 

SGL Carbon Croup/SGL Technic 


R. Lewandowski 

Corrosion Resistant Composites 


T. Bonn 

Carbone of America 


H. Marsh 
Consultant 




J. Richter 

FEMech Engineering 




D. Cook 

State of California 




N. Newhouse 
Lincoln Composites 




D. Hodgkinson 
Consultant 




M. Gorman 
Digital Wave 




R. Crawford 
L&M Fiberglass 



T. Cowley 
Dupont 



NATIONAL BOARD INSPECTION CODE 



National Board Inspection Code 
2007 Edition including 2008 and 2009 Addendum 

Date of Issue — December 31, 2009 

This code was developed under procedures accredited as meeting the criteria for American 
National Standards. The Consensus Committee that approved the code was balanced to ensure 
that individuals from competent and concerned interests had an opportunity to participate. The 
proposed code was made available for public review and comment, which provided an 
opportunity for additional public input from industry, academia, regulatory and jurisdictional 
agencies, and the public-at-large. 

The National Board does not "approve," "rate," or "endorse" any item, construction, 
proprietary device, or activity. 

The National Board does not take any position with respect to the validity of any patent rights 
asserted in connection with any items mentioned in this document, and does not undertake 
to insure anyone utilizing a standard against liability for infringement of any applicable Letters 
Patent, nor assume any such liability. Users of a code are expressly advised that determination 
of the validity of any such patent rights, and the risk of infringement of such rights, is entirely 
their own responsibility. 

Participation by federal agency representative(s) or person(s) affiliated with industry is not to be 
interpreted as government or industry endorsement of this code. 

The National Board accepts responsibility for only those interpretations issued in accordance 
with governing National Board procedures and policies that preclude the issuance of 
interpretations by individual committee members. 

The footnotes in this document are part of this American National Standard. 



M 




R 



w 



® 



The above National Board symbols are registered with the US Patent Office. 

"National Board" is the abbreviation for The National Board of Boiler and Pressure Vessel 
Inspectors. 

No part of this document may be reproduced in any form, in an electronic retrieval system or 
otherwise, without the prior written permission of the publisher. 



XI 



NATIDNAL BOARD INSPECTION CDDE 



NATIONAL BOARD INSPECTION CODE 



Foreword 

The National Board of Boiler and Pressure Vessel Inspectors is an organization comprised of 
Chief Inspectors for the states, cities, and territories of the United States and provinces and 
territories of Canada. It is organized for the purpose of promoting greater safety to life and 
property by securing concerted action and maintaining uniformity in post-construction 
activities of pressure-retaining items, thereby ensuring acceptance and interchangeability 
among Jurisdictional authorities responsible for the administration and enforcement of various 
codes and standards. 

In keeping with the principles of promoting safety and maintaining uniformity, the National 
Board originally published The NBIC in 1 946, establishing rules for inspection and repairs to 
boilers and pressure vessels. The National Board Inspection Code (NBIC) Committee is charged 
with the responsibility for maintaining and revising the NBIC. In the interest of public safety, 
the NBIC Committee decided, in 1 995, to revise the scope of the NBIC to include rules for 
installation, inspection, and repair or alteration to boilers, pressure vessels, piping, and 
nonmetallic materials. 

In 2007, the NBIC was restructured into three Parts specifically identifying important post- 
construction activities involving safety of pressure-retaining items. This restructuring provides for 
future expansion, transparency, and uniformity, ultimately improving public safety. 

The NBIC Committee's function is to establish rules of safety governing post-construction activities 
for the installation, inspection and repair and alteration of pressure-retaining items, and to interpret 
these rules when questions arise regarding their intent. In formulating the rules, the NBIC 
Committee considers the needs and concerns of individuals and organizations involved in the 
safety of pressure-retaining items. The objective of the rules is to afford reasonably certain 
protection of life and property, so as to give a reasonably long, safe period of usefulness. 
Advancements in design and material and the evidence of experience are recognized. 

The rules established by the NBIC Committee are not to be interpreted as approving, 
recommending, or endorsing any proprietary or specific design, or as limiting in any way an 
organization's freedom to choose any method that conforms to the NBIC rules. 

The NBIC Committee meets regularly to consider revisions of existing rules, formulation of new 
rules, and respond to requests for interpretations. Requests for interpretation must be addressed 
to the NBIC Secretary in writing and must give full particulars in order to receive Committee 
consideration and a written reply. Proposed revisions to the Code resulting from inquiries will 
be presented to the NBIC Committee for appropriate action. 

Proposed revisions to the Code approved by the NBIC Committee are submitted to the 
American National Standards Institute and published on the National Board Web site to 
invite comments from all interested persons. After the allotted time for public review and final 
approval, revisions are published annually in Addenda to the NBIC. 

Organizations or users of pressure-retaining items are cautioned against making use of 
revisions that are less restrictive than former requirements without having assurance that they 
have been accepted by the Jurisdiction where the pressure-retaining item is installed. 



XIII 



NATIONAL BDARD INSPECTION CODE 



The general philosophy underlying the NBIC is to parallel those provisions of the original code 
of construction, as they can be applied to post-construction activities. 

The NBIC does not contain rules to cover all details of post-construction activities. Where 
complete details are not given, it is intended that individuals or organizations, subject to the 
acceptance of the Inspector and Jurisdiction when applicable, provide details for post- 
construction activities that will be as safe as otherwise provided by the rules in the original 
Code of Construction. 

Activities not conforming to the rules of the original code of construction or the NBIC must 
receive specific approval of the Jurisdiction, who may establish requirements for design, 
construction, inspection, testing, and documentation. 

There are instances where the NBIC serves to warn against pitfalls; but the Code is not a hand- 
book, and cannot substitute for education, experience, and sound engineering judgment. 

It is intended that this Edition of the NBIC and any subsequent Addenda not be retroactive. 
Unless the Jurisdiction imposes the use of an earlier edition, the latest effective edition and 
addenda is the governing document. 



XIV 



NATIONAL BOARD INSPECTION CODE 



Introduction 

It is the purpose of the National Board Inspection Code (NBIC) to maintain the integrity of 
pressure-retaining items by providing rules for installation, and after the items have been 
placed into service, by providing rules for inspection and repair and alteration, thereby 
ensuring that these items may continue to be safely used. 

The NBIC is intended to provide rules, information and guidance to manufacturers, 
Jurisdictions, inspectors, owner-users, installers, contractors, and other individuals and 
organizations performing or involved in post-construction activities, thereby encouraging the 
uniform administration of rules pertaining to pressure-retaining items. 

Scope 

The NBIC recognizes three important areas of post-construction activities where information, 
understanding, and following specific requirements will promote public and personal safety. 
These areas include: 

• Installation 

• Inspection 

• Repairs and Alterations 

The NBIC provides rules, information, and guidance for post-construction activities, but does 
not provide details for all conditions involving pressure-retaining items. Where complete de- 
tails are not provided in this Code, the Code user is advised to seek guidance from the Jurisdic- 
tion and from other technical sources. 

The words shall, should, and may are used throughout the NBIC and have the following intent: 

• Shall - action that is mandatory and required. 

• Should - indicates a preferred but not mandatory means to accomplish the requirement 
unless specified by others such as the Jurisdiction. 

• May - permissive, not required or a means to accomplish the specified task. 

Organization 

The NBIC is organized into three Parts to coincide with specific post-construction activities 
involving pressure-retaining items. Each Part provides general and specific rules, information, 
and guidance within each applicable post-construction activity. Other NBIC Parts or other 
published standards may contain additional information or requirements needed to meet the 
rules of the NBIC. Specific references are provided in each Part to direct the user where to find 
this additional information. NBIC Parts are identified as: 

9 Part 1, Installation -This Part provides requirements and guidance to ensure all types of 
pressure-retaining items are installed and function properly. Installation includes 
meeting specific safety criteria for construction, materials, design, supports, safety 
devices, operation, testing, and maintenance. 

• Part 2, Inspection -This Part provides information and guidance needed to perform and 
document inspections for all types of pressure-retaining items. This Part includes 
information on personnel safety, non-destructive examination, tests, failure 
mechanisms, types of pressure equipment, fitness for service, risk-based assessments, 
and performance-based standards. 



XV 



NATIONAL BOARD INSPECTION CODE 



• Part 3, Repairs and Alterations -This Part provides information and guidance to 
perform, verify, and document acceptable repairs or alterations to pressure-retaining 
items regardless of code of construction. Alternative methods for examination, testing, 
heat treatment, etc., are provided when the original code of construction requirements 
cannot be met. Specific acceptable and proven repair methods are also provided. 

Each NBIC Part is divided into major Sections as outlined in the Table of Contents. 

Tables, charts, and figures provide relevant illustrations or supporting information for text 
passages, and are designated with numbers corresponding to the paragraph they illustrate or 
support within each Section. Multiple tables, charts, or figures referenced by the same 
paragraph will have additional letters reflecting the order of reference. Tables, charts, and 
figures are located in or after each major Section within each NBIC Part. 



Text Identification and Numbering 

Each page in the text will be designated in the top header with the publication's name, part 
number, and part title. The numbering sequence for each section begins with the section 
number followed by a dot to further designate major sections (e.g., 1 .1, 1 .2, 1 .3). Major 
sections are further subdivided using dots to designate subsections within that major section 
(e.g., 1.1.1, 1 .2.1 , 1 .3.1 ). Subsections can further be divided as necessary. 

Paragraphs under sections or subsections shall be designated with small letters in parenthesis 
(e.g., a), b), c)) and further subdivided using numbers in parenthesis (e.g., 1), 2), 3)). 
Subdivisions of paragraphs beyond this point will be designated using a hierarchical sequence 
of letters and numbers followed by a dot. 

Example: 2.1 Major Section 

2.1.1 Section 

2.1.2 Section 

2.1.2. Subsection 

a) paragraph 

b) paragraph 

1) subparagraph 

2) subparagraph 

a. subdivisions 

1. subdivisions 

2. subdivisions 

b. subdivisions 

1 . subdivisions 

2. subdivisions 

Tables and figures will be designated with the referencing section or subsection identification. 
When more than one table or figure is referenced in the same section or subsection, letters or 
numbers in sequential order will be used following each section or subsection identification. 



XVI 



NATIONAL BOARD INSPECTION CODE 



Supplements 

Supplements are contained in each Part of the NBIC to designate information only pertaining to 
a specific type of pressure-retaining item (e.g., Locomotive Boilers, Historical Boilers, Graphite 
Pressure Vessels.) Supplements follow the same numbering system used for the main text only 
preceded by the Letter "S." Each page of the supplement will identify the supplement number 
and name in the top heading. 



Addenda 

Addenda, which include revisions and additions to this Code, are published annually. Addenda 
are permissive on the date issued and become mandatory six months after the date of issue. 
The addenda will be sent automatically to purchasers of the Code up to the publication of the 
next edition. Every three years the NBIC is published as a new edition that includes that year's 
addenda. 



Interpretations 

On request, the NBIC Committee will render an interpretation of any requirement of this Code. 
Interpretations are provided for each Part and are specific to the Code edition and addenda 
referenced in the interpretation. Interpretations provide information only and are not part of 
this Code. 



Jurisdictional Precedence 

Reference is made throughout this Code to the requirements of the "Jurisdiction." Where any 
provision herein presents a direct or implied conflict with any jurisdictional regulation, the 
Jurisdictional regulation shall govern. 



Units of Measurement 

Both U.S. customary units and metric units are used in the NBIC. The value stated in U.S. custom- 
ary units or metric units are to be regarded separately as the standard. Within the text, the met- 
ric units are shown in parentheses. In supplement 6, Continued Service and Inspection of DOT 
Transport Tanks, the metric units are shown first with the U.S. customary units shown in parentheses. 

U.S. customary units or metric units may be used with this edition of the NBIC, but one system 
of units shall be used consistently throughout a repair or alteration of pressure-retaining items. 
It is the responsibility of National Board accredited repair organizations to ensure the 
appropriate units are used consistently throughout all phases of work. This includes materials, 
design, procedures, testing, documentation, and stamping. The NBIC policy for metrication is 
outlined in each part of the NBIC. 



Accreditation Programs 

The National Board administers and accredits three specific repair programs 1 as shown below: 

"R" Repairs and Alterations to Pressure-Retaining Items 

"VR" Repairs to Pressure Relief Valves 

"NR" Repair and Replacement Activities for Nuclear Items 



1 Caution, some Jurisdictions may independently administer a program of authorization for organizations to perform repairs and 
alterations within that Jurisdiction. 



NATIONAL BOARD INSPECTION CODE 

Part 3, Repairs and Alterations, of the NBIC describes the administrative requirements for the 
accreditation of these repair organizations. 

The National Board also administers and accredits four specific inspection agency programs as 
shown below: 

New Construction 

Criteria for Acceptance of Authorized Inspection Agencies for New Construction 

(NB-360) 
In service 

Qualifications and Duties for Authorized Inspection Agencies (AlAs) Performing Inservice 

Inspection Activities and Qualifications for Inspectors of Boilers and Pressure Vessels 

(NB-369) 
Owner-User 

Accreditation of Owner-User Inspection Organizations (OUIO) (NB-371 ) Owners or users 

may be accredited for both a repair and inspection program provided the requirements 

for each accreditation program are met. 
Federal Government 

Qualifications and Duties for Federal Inspection Agencies Performing Inservice Inspection 

Activities (FIAs) (NB-390) 



These programs can be viewed on the National Board Web site. For questions or further infor- 
mation regarding these programs contact: 

The National Board of Boiler and Pressure Vessel Inspectors 

1055 Crupper Avenue 

Columbus, OH 43229-1183 

Phone — 614.888.8320 

Fax — 614.847.1828 

Web site — www.nationalboard.org 



Certificates of Authorization for Accreditation Programs 

Any organization seeking an accredited program may apply to the National Board to obtain a 

Certificate of Authorization for the requested scope of activities. A confidential review shall be 

conducted to evaluate the organization's quality system. Upon completion of the evaluation, 

a recommendation will be made to the National Board regarding issuance of a Certificate of 

Authorization. 

Certificate of Authorization scope, issuance, and revisions for National Board accreditation 
programs are specified in the applicable National Board procedures. When the quality system 
requirements of the appropriate accreditation program have been met, a Certificate of 
Authorization and appropriate National Board symbol stamp shall be issued. 



XVIII 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



1 .7.6.3 Return of Stamp 25 

1 .7.6.4 Multiple Locations 25 

1.7.6.5 Certificate of Authorization Contents 25 

1.7.6.6 Changes to Certificates of Authorization 25 

1 .7.6.7 Issuance of More Than One "VR" Symbol Stamp to a 
Certificate of Authorization Holder 25 

1 .7.7 Quality System 25 

1.7.7.1 General 25 

1.7.7.2 Written Description 26 

1 .7.7.3 Review 26 

1 .7.7.4 Maintenance of Controlled Copy 26 

1 .7.7.5 Outline of Requirements for a Quality System 26 

1 .7.8 ASME "V," "HV," or "UV" Certificate Holders 29 

1.8 "NR" Accreditation Requirements 30 

1.8.1 Scope 30 

1 .8.2 Prerequisites for Issuing a National Board "NR" Certificate of 
Authorization 30 

1 .8.3 Procedures for Obtaining or Renewing a National Board "NR" 
Certificate of Authorization 31 

1 .8.4 National Board "NR" Symbol Stamp 33 

1 .8.5 Quality System Program 33 

1 .8.5.1 Outline of Requirements for a Quality System 

Program for Qualification for the National Board 

"NR" Symbol Stamp 33 

1 .8.6 Interface with the Owner's Repair/Replacement Program 40 

Section 2 Welding and Heat Treatment 41 

2.1 Scope 42 

2.2 Welding 42 

2.2.1 Welding Procedure Specifications 42 

2.2.2 Standard Welding Procedure Specifications 42 

2.2.3 Performance Qualification 42 

2.2.4 Welding Records 42 

2.2.5 Welder's Identification 42 

2.2.6 Welder's Continuity 43 

2.3 Standard Welding Procedure Specifications 43 

2.4 AWS Reference Standards 50 

2.5 Heat Treatment 50 

2.5.1 Preheating 50 

2.5.2 Postweld Heat Treatment (PWHT) 52 

2.5.3 Alternative Welding Methods Without Postweld Heat Treatment 52 

2.5.3.1 Welding Method 1 54 

2.5.3.2 Welding Method 2 54 

2.5.3.3 Welding Method 3 55 

2.5.3.4 Welding Method 4 56 

2.5.3.5 Welding Method 5 58 

Section 3 Requirements for Repairs and Alterations 59 

3.1 Scope 60 

3.2 General Requirements for Repairs and Alterations 60 

3.2.1 Material Requirements for Repairs and Alterations 60 

3.2.2 Replacement Parts 60 

3.2.3 Drawings 61 

3.2.4 Design Requirements for Repairs and Alterations 61 

3.2.5 Calculations 62 

3 



NATIDNAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



3.2.6 Reference to other Codes and Standards 62 

3.3 Repairs to Pressure-Retaining Items 62 

3.3.1 Defect Repairs 62 

3.3.2 Routine Repairs 62 

3.3.3 Examples of Repairs 63 

3.3.4 Repair Methods 64 

3.3.4.1 Scope 64 

3.3.4.2 Defect Repairs 64 

3.3.4.3 Wasted Areas 66 

3.3.4.4 Seal Welding 72 

3.3.4.5 Re-Ending or Piecing Pipes or Tubes 72 

3.3.4.6 Patches 72 

3.3.4.7 Stays 74 

3.3.4.8 Repair of Pressure-Retaining items without Complete 
removal of Defects 74 

3.3.5 Repair of ASME Section VIII, Division 2 or 3, Pressure Vessels 75 

3.3.5.1 Scope 75 

3.3.5.2 Repair Plan 75 

3.4 Alterations 76 

3.4.1 Re-Rating 76 

3.4.2 Alterations Based on Allowable Stress Values 76 

3.4.3 Examples of Alterations 76.1 

3.4.4 Alteration of ASME Code Section VIII, Division 2 or 3, 

Pressure Vessels 76.1 

3.4.4.1 Alteration Plan 76.1 

Section 4 Examination andTesting 77 

4.1 Scope 78 

4.2 Nondestructive Examination 78 

4.3 Pressure Gages, Measurement, Examination, and Test Equipment 78 

4.4 Examination and Test for Repairs and Alterations 78 

4.4.1 Test or Examination Methods Applicable to Repairs 79 

4.4.2 Test or Examination Methods Applicable to Alterations 80 

4.5 Pressure Relief Valve Performance Testing andTesting Equipment 81 

4.5.1 Test Medium and Testing Equipment 81 

4.5.2 Owner-User ASME Code Section VIII Steam Testing 82 

4.5.3 Lift Assist Testing 82 

4.5.4 Pressure Test of Parts 82 

Section 5 Certification/Documentation and Stamping 85 

5.1 Scope 86 

5.2 Documentation 86 

5.2.1 Preparation of Form R-1 (Repairs) 86 

5.2.2 Preparation of Form R-2 (Alterations) 86 

5.3 Distribution of Form R-1 87 

5.4 Distribution of Form R-2 87 

5.5 Registration of "R" Forms - General 87 

5.5.1 Registration for Repairs 87 

5.5.2 Registration for Alterations 87 

5.5.3 Registration for Fiber-Reinforced Vessels 88 

5.5.4 Registration for Nuclear Repair/Replacement Activities 88 

5.5.5 Registration for Graphite Vessels 88 

5.6 Form "R" Log 88 

5.7 Stamping Requirements for Repairs and Alterations 88 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



5.7.1 General 88 

5.7.2 Stamping Requirements for Repairs 88 

5.7.3 Stamping Requirements for Alterations and Re-ratings 88 

5.7.4 Stamping Requirements for Parts 89 

5.7.5 Specific Requirements of Stamping and Nameplates 89 

5.8 Removal of Original Stamping or Nameplate 89 

5.9 Stamping Requirements for Pressure Relief Devices 89 

5.9.1 Nameplates 89 

5.9.2 Repair Nameplate 89 

5.9.3 Changes to Original Pressure Relief Valve Nameplate Information ... 90 

5.9.4 Test Only Nameplate 90 

5.9.5 Replacement of Illegible or Missing Nameplates 91 

5.10 Alternative Marking and Stamping for Graphite Pressure Equipment 91 

5.1 1 Stamping for Fiber Reinforced Vessels 92 

5.11.1 Removal of Original Stamping or Nameplate 92 

5.1 1 .2 Stamping for Repairs 92 

5.1 1.3 Stamping for Alterations 93 

5.12 Stamping Requirements for Yankee Dryers 93 

5.13 Repair and Alteration Forms and Guidelines for Completing Forms 94 

5.13.1 Form R-1 Report of Repair 95 

5.1 3.2 Form R-2 Report of Alteration 96 

5.13.3 Form R-3 Report of Fabricated Parts 98 

5.13.4 Form R-4 Report Supplementary Sheet 100 

5.13.4.1 Guide for Completing National Board 

Form "R" Reports 101 

5.1 3.5 Form NR-1 Nuclear Components and Systems in Nuclear 

Power Plants 104 

5.13.6 Form NVR-1 Nuclear Pressure Relief Devices 106 

5.1 3.6.1 Guide for Completing National Board Form NR-1 

and NVR-1 Reports 107 

Section 6 Supplements 109 

Supp. 1 Steam Locomotive Firetube Boiler Repairs 1 1 

SI .1 General Requirements 110 

51 .1 .1 Federal Railroad Administration (FRA) 1 1 

51.1.2 Requirements for Welding Activities 1 10 

51.1.3 Materials 110 

S1 .1 .3.1 Material List for Steam Locomotive Boilers 1 1 1 

51 .1 .4 Formula and Calculations for Steam Locomotive Boilers 1 1 1 

S1 .2 Locomotive Firetube Boiler Repairs 1 12 

51.2.1 Repair of Staybolt Holes 112 

51 .2.2 Threaded Staybolts 112 

51 .2.3 Ball Socket-Type Flexible Staybolts, Sleeves, and Caps 1 13 

51.2.4 Seal Welded Staybolts 116 

51 .2.5 Welded Installation of Staybolts 1 1 6 

51 .2.6 Diagonal Braces, Gusset Braces, and Throat 

Sheet/Tubesheet Braces 1 1 7 

51 .2.6.1 Girder Stays and Crown Bars 1 1 7 

51 .2.6.2 Sling Stays 118 

51 .2.6.3 Expansion Stays 1 18 

51.2.7 Threaded Studs 118.1 

51.2.8 Patch Bolts 118.1 

51 .2.9 Flues, Arch Tubes, Circulators, Thermic Siphons 1 18.1 

51 .2.9.1 Flue and Tube Re-Ending 1 1 8.1 

51.2.9.2 Arch Tubes 119 

5 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



51.2.9.3 Tube Wall Thickness for Arch Tubes 119 

51.2.9.4 Thermic Siphons 119 

51.2.9.5 Circulators 119 

51 .2.9.6 Re-rolling of Flue-tubes after Seal Welding 1 1 9 

51 .2.9.7 Ferrules 120 

SI .2.1 Repairs and Alterations to Boiler Barrel Unstayed Areas 120 

S1.2.1 1 Repairs and Alterations to Boiler Barrel Stayed Area 122 

51 .2.1 1 .1 Firebox Sheet Repair 122 

51 .2.1 1 .2 Firebox Patches 122 

51 .2.1 1 .3 Repair of Stayed Firebox Sheets Grooved or 

Wasted at the Mudring 123 

51 .2.1 1.4 Mudring Repairs 126 

51.2.1 1.5 Repair of Firebox andTubesheet Knuckles 126 

51 .2.1 1.6 Tubesheet Repairs 127 

SI .2.12 Seams and Joints 127 

51 .2.12.1 Caulking Riveted Seams and Rivet Heads 127 

51 .2.1 2.2 Threaded Openings in Vessel Walls, Bushings, 
and Welded Nozzles (Washout Plug Holes and 

Other Connections) 127 

SI .2.1 3 Fittings and Gages 128 

51 .2.13.1 Water Gage Connection 128 

Supp. 2 Historical Boilers 128.2 

52.1 Scope 128.2 

52.2 Introduction 128.2 

52.3 Responsibilities 128.2 

52.4 Repairs and Alterations 128.2 

52.5 Construction Standards 128.2 

52.6 Accreditation 129 

52.7 Materials 129 

52.7.1 Material List for Historical Boilers Repairs 129 

52.7.2 Replacement Parts 130 

52.8 Welded Repair Inspection 130 

52.9 Welding 130 

52.10 Heat Treatment 130 

52.1 1 Nondestructive Examination 130 

52.12 Documentation 130 

52.13 Repair Methods 131 

52.13.1 Repair of Threaded Staybolt Holes 131 

52.13.2 Installation ofThreaded Staybolts 131 

52.13.3 Seal Welding ofThreaded Staybolts 132 

52.13.4 Installation ofWelded Staybolts 132 

52.13.5 Threaded Studs 133 

52.13.6 Patch Bolts 134 

52.13.7 Flue andTube Re-Ending 134 

52.13.8 Flue andTube Installation 134 

52.1 3.9 Repairs and Alterations to Unstayed Areas 1 36 

S2.1 3.9.1 Weld Buildup of Wastage and Grooving in 

Unstayed Areas 136 

52. 13.9.2 Welded Repair of Cracks in Unstayed Areas 137 

52.13.9.3 Welded Flush Patches in Unstayed Areas 137 

S2.1 3.9.4 Repair of Cracks, Grooving, and Wastage Using a 

Riveted Patch in Unstayed Areas 138 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



52.13.10 Repairs and Alterations to Stayed Areas 139 

52.13.10.1 Weld Buildup of Wastage and Grooving in 

Stayed Areas 139 

52. 13. 10.2 Welded Repair of Cracks in Stayed Areas 139 

52.1 3.1 0.3 Welded Flush Patches in Stayed Areas 139 

52.1 3.1 0.4 Repair of Stayed Firebox Sheets Grooved or Wasted 

at the Mudring 140 

52.13.1 1 Repair of Firebox andTubesheet Knuckles 141 

52. 13. 11.1 Weld Buildup of Wastage and Grooving in Firebox 
andTubesheet Knuckles 141 

52.1 3.1 1 .2 Welded Repair of Cracks in Firebox and Tubesheet 
Knuckles 141 

52.13.1 1.3 Welded Flush Patches in Firebox andTubesheet 
Knuckles 142 

52.13.12 Repair of Tubesheets 142 

52.13.12.1 Weld Buildup of Wastage and Grooving 

in Tubesheets 142 

52.13.12.2 Welded Repair of Cracks inTubesheets 142 

52. 13.12.3 Welded Flush Patches inTubesheets 144 

52.13.13 Seams, Joints, and Rivets 145 

52. 13. 13.1 Caulking Riveted Seams and Rivet Heads 145 

52. 13. 13.2 Rivet Holes 145 

52.1 3.13.3 Assembly of Riveted Joints 145 

52. 13. 13.4 Riveting 145 

52.1 3.1 3.5 Seal Welding Seam, Joints, and Rivet Heads 146 

52.13.14 Repair of Openings 146 

52. 13. 14.1 Repair ofThreaded Openings 146 

52.1 3.14.2 Repair of Handhole Openings 149 

52.13.14.3 Repair of Fusible Plug Opening 150 

Supp. 3 Repair and Alteration of Graphite Pressure Equipment 1 51 

53.1 Scope 151 

53.2 Repairs 151 

53. 3 Repairs of a Routine Nature 153 

53. 4 Alterations 153 

53. 5 Repair Guide for Impervious Graphite 153 

53. 5.1 Introduction 153 

53. 5. 2 Typical Graphite Fractures 154 

53. 5. 2.1 Major Fracture 154 

53. 5. 2. 2 Intermediate Fracture 154 

53. 5. 2. 3 Minor Fracture 154 

53. 5. 3 Graphite Repair by Plug Stitching 157 

53. 5. 3.1 Plug Stitching Procedure 157 

53. 5. 3. 2 Figures -Typical Plug Stitching Procedure 158 

53. 5. 4 Re-impregnation of Graphite Parts (Tubesheets, Heads, 

and Blocks) 158 

53. 5. 4.1 Control of Impregnation Material 159 

53. 5. 4.2 Finishing the Repair 159 

Supp. 4 Repair and Alteration of Fibe^Reinforced Thermosetting Plastic 

Pressure Equipment 160 

54.1 Scope 160 

54.2 Inspector Qualifications 160 

54.3 Tools 160 

54.4 Limitations 161 

54.5 Repair Limitations for Filament Wound Vessels 1 61 

54.6 Vessels Fabricated Using Elevated Temperature Cured Resin Systems 1 61 



NATIONAL BOARD INSPECTION CODE ' PART 3 — REPAIRS AND ALTERATIONS 



54.7 Code of Construction 161 

54.8 Materials 162 

54.9 Replacement Parts 162 

54.10 Secondary Bonding 162 

54.10.1 > Secondary Bonding Procedure Specifications 162 

54.10.2 Performance Qualifications 162 

54.10.3 Records 162 

54.10.4 Secondary Bonder's Identification 163 

54.10.5 Secondary Bonder's Continuity 163 

54.1 1 Curing 163 

54.12 Nondestructive Examination 163 

54.13 Pressure and Acoustic Emission Tests 163 

S4.13.1 Pressure Gages, Measurement, and Examination 

and Test Equipment 163 

54.14 Acceptance Inspection 168 

54.14.1 Stamping 168 

54.14.2 Documentation 168 

54.14.3 Registration of Documentation 168 

54.14.4 Distribution of Documentation 168 

54.15 Pressure Testing For Repairs 168 

54.1 6 Additional Requirements for Repairs 1 69 

54.16.1 Scope 169 

54.16.2 Drawings 169 

54.16.3 Repair Plan 169 

54.16.4 Routine Repairs 169 

54.16.5 Repair Methods 170 

54.17 Additional Requirements for Alterations 170 

54.17.1 Scope 170 

54.17.2 Design 170 

54.17.3 Alteration Plan 170 

54.17.4 Calculations 170 

54.17.5 Re-Rating 171 

S4.1 7.6 Pressure Testing 1 71 

54.18 Repair and Alteration Methods 1 72 

54.18.1 General Requirements 172 

54.18.2 Classification of Repairs 1 72 

54.1 8.2.1 Type 1 a - Repair of the Corrosion Barrier 1 73 

54. 18.2.2 Type 1b - Repair of the Corrosion Barrier for Vessels 

with Precision Bores 175 

54.1 8.2.3 Type 2 - Corrosion Barrier and Internal 

Structural Layer Repairs 1 77 

S4.1 8.2.4 Type 3 - External Structural Layer Repairs 1 77 

S4.18.2.5 Type 4 - Alterations 179 

S4.1 8.2.6 Type 5 - Miscellaneous General External 

Repairs or Alterations 179 

54.1 8.2.7 Type 6 -Thermoplastic Repairs 1 79 

54.1 8.2.8 Type 7 - Gel Coat Repairs 1 79 

Supp. 5 General Requirements for Repairs and Alterations to Yankee Dryers 181 

55.1 Scope 181 

55.2 Examinations and Test Methods 181 

55.3 Yankee Dryer Repair Methods 181 

S5.3.1 Replacement Parts for Yankee Dryers 181 

55.4 Repair Guide for Yankee Dryers 181 

55.5 Procedures That Do Not Require Stamping or Nameplate Attachment 1 82 

55.6 Damage Repair 182 



NATIONAL BOARD INSPECTION CODE * PART 3 — REPAIRS AND ALTERATIONS 



55.6.1 Repair of Local Thinning 182 

55.6.2 Treatment of Crack-Like Flaws 1 83 

55.6.3 Driven Plug Repair 184 

55.6.4 Treaded Plug Repair 184 

S5.7 Alterations to Yankee Dryers 184 

55.7.1 Scope 184 

55.7.2 Alteration Types 184 

Supp. 6 Repair, Alteration, and Modification of DOT Transport Tanks 185 

56.0 General Requirements 185 

56.1 Scope 185 

56.2 Construction Standards 185 

56.3 Accreditation 185 

56.4 Materials 185 

56.5 Replacement Parts 185 

56.6 Authorization 186 

56.7 Inspection 186 

S6.7.1 Inspector Duties for Repairs, Alterations, and Modifications 1 86 

56.8 Welding 187 

56.8.1 Welding Procedure Specification 187 

56.8.2 Standard Welding Procedure Specifications 1 87 

56.8.3 Performance Qualification 188 

56.8.4 Welding Records 188 

56.8.5 Welder's Identification 188 

56.8.6 Welder's Continuity 188 

56.9 Heat Treatment 188 

56.9.1 Preheating 188 

56.9.2 Postweld Heat Treatment 188 

56.9.3 Alternatives to Postweld Heat Treatment 189 

56.10 Nondestructive Examination 189 

56.1 1 Coatings and Linings 190 

56.12 Measurement, Examination, andTest Equipment 190 

56.13 Acceptance Inspection 190 

56.14 Stamping 190 

S6.14.1 Removal of Original Stamping or Nameplate 190 

56.15 "TR" Forms 190 

56.15.1 Registration of "TR" Forms 190 

56.15.2 Form "TR" Log 190 

56.1 6 Additional Requirements for Repairs, Alterations, or Modifications 1 91 

56.16.1 Scope 191 

56.16.2 Repairs of Defects 191 

56.16.3 Modifications 191 

56.16.4 Drawings 191 

56.16.5 Authorization 191 

S6.1 7 Examination andTest 191 

56.17.1 Methods 191 

56.17.2 Stamping 192 

S6.1 7.3 Documentation 1 92 

56.18 Preparation ofTR Forms 192 

56.18.1 Distribution 192 

56.18.2 Registration 192 

56.19 Repairs, Alterations, or Modification Reports 192 

56.19.1 Registration of FormTR-1 and FormTR-2 193 

56.1 9.2 General Requirements "TR" Stamping and Nameplates 1 93 

56.19.3 Stamping of the "TR" Symbol 194 

Supp. 7 Requirements for Repairs to Pressure Relief Devices 1 95 

9 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



57.1 Scope 195 

57.2 General Requirements 195 

57.3 Weld Repairs to Pressure ReliefValve Parts 195 

57.4 Materials for Pressure Relief Devices 196 

57.5 Replacement Parts for Pressure Relief Devices 196 

57.6 Initial Adjustments to Pressure Relief Valves 1 97 

57.7 Field Repair 197 

57.8 Audit Requirements 197 

57.9 Use of Owner-User Personnel 197 

57.1 Guide to Jurisdictions for Authorization of Owners-Users to Make 
Adjustments to Pressure Relief Valves 198 

57.10.1 General 198 

57.10.2 Training 198 

57.10.3 Documentation 198 

57.10.4 Quality System 198 

57.10.5 External Adjustments 198 

57.10.6 Repairs 199 

57.1 1 Training and Qualification of Personnel 199 

57.11.1 General 199 

57.1 1 .2 Contents of Training Program 199 

57.1 1 .3 Qualification of Personnel 199 

57.11.4 Annual Review of Qualification 199 

57.12 Welding for Pressure ReliefValves 199 

57.12.1 Welding Procedure Specifications 200 

57.12.2 Standard Welding Procedure Specifications 200 

57.12.3 Performance Qualification 200 

57.12.4 Welding Records 200 

57.12.5 Welders' Identification 200 

57.12.6 Welders' Continuity 200 

57.13 Heat Treatment 200 

57.13.1 Preheating 200 

57.13.2 Postweld Heat Treatment 201 

57.14 Recommended Procedures for Repairing Pressure ReliefValves 201 

57.14.1 Introduction 201 

57.14.2 Spring-Loaded Pressure ReliefValves 201 

57.14.3 Pilot Operated Safety ReliefValves 203 

Supp. 8 Recommended Guide for the Design of a Test System for Pressure 

Relief Devices in Compressible Fluid Service 206 

58.1 Introduction 206 

58.2 General 206 

58.3 Test System Description 206 

58.4 TestVessel Sizing Data 208 

58.5 Tables, Charts, and Figures 208 

Supp. 9 Procedures to Extend the "VR" Certificate of Authorization and Stamp 

to ASME "NV" Stamped Pressure Relief Devices 210 

59.1 Introduction 210 

59.2 Administrative Procedures 210 

59.3 General Rules 210 

Supp. 1 Repair and Alterations of Pressure Vessels in Liquefied Petroleum 

Gas Service 212 

510.1 Scope 212 

510.2 General and Administrative Requirements 212 

510.3 Welding 212 



1 D 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



510.4 Requirements for Repairs and Alterations 212 

510.5 Examination and Testing 212 

510.6 Certification/Documentation and Stamping 212 

510.7 Inspection 212.1 

510.8 Coatings 212.1 

Section 7 NBIC Policy for Metrication 213 

7.1 General 214 

7.2 Equivalent Rationale 214 

7.3 Procedure for Conversion 214 

7.4 Referencing Tables 215 

Section 8 Preparation of Technical Inquiries to the National Board 

Inspection Code Committee 219 

8.1 Introduction 220 

8.2 Inquiry Format 220 

8.3 Code Revisions or Additions 221 

8.4 Code Interpretations 221 

8.5 Submittals 221 

Section 9 Glossary of Terms 223 

9.1 Definitions 224 

Section 10 NBIC Approved Interpretations 227 

10.1 SCOPE 228 

1 0.2 Index of Interpretations 228 

10.3 Subject Index of Interpretations 232 

Section 1 1 Index 235 



l i 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



1 Z 



NATIONAL BDARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



Report Form 3 upon completion of the 
work. 

o) Inspections 

The manual shall make provisions for the 
Inspector to have access to all drawings, 
design calculations, specifications, proce- 
dures, process sheets, repair or alteration 
procedures, test results, and other docu- 
ments as necessary to ensure compliance 
with the NBIC. A copy of the current man- 
ual shall be available to the inspector. 

p) Report of Repair or Alteration Form 

The manual shall indicate the title of the 
individuals responsible for preparing, 
signing, and presenting the NBIC Report 
Forms to the Inspector. The distribution of 
the NBIC Report Forms 3 shall be described 
in the manual. 

q) Exhibits 

Any forms referenced in the manual shall 
be included. The form may be a part of 
the referencing document or included as 
an appendix. For clarity, the forms may be 
completed and identified as examples. The 
name and accepted abbreviations of the 
"R" Certificate Holder shall be included in 
the manual. 

r) Construction Code 

The manual shall include provisions for 
addressing the requirements that pertain 
to the specific construction code for the 
equipment being repaired or altered. 

s) Nonconforming Items 

There shall be a system acceptable to 
the Inspector for the correction of non- 
conformities. A nonconformance is any 
condition that does not comply with the 
applicable rules of the NBIC, construction 
code, jurisdictional requirements, or the 
quality system. Nonconformance must be 
corrected or eliminated before the repaired 



or altered component can be considered in 
compliance with the NBIC. 



1 .7 ACCREDITATION OF "VR" 

REPAIR ORGANIZATIONS 



1.7.1 



SCOPE 



3 NBIC Report Form: National Board Form R-1 for Repairs, 
Form R-2 for Alterations, or Form R-3 for Fabricated Parts. 



a) These administrative rules and procedures 
are provided for those who wish to obtain 
a National Board Certificate of Authoriza- 
tion for use of the "VR" (Repair of Pressure 
Relief Valves) symbol stamp. It should be 
noted that the issuance of the "VR" stamp 
is not restricted to companies whose pri- 
mary business is the repair of pressure relief 
valves, nor to manufacturers or assemblers 
that hold an ASME "V," "HV," "UV," or "NV" 
Code symbol stamp. Owners and users of 
boilers and pressure vessels and other or- 
ganizations that qualify in accordance with 
the National Board Rules and Regulations 
may also obtain the "VR" Certificate and 
stamp. 

b) In order to provide due process in the is- 
suance, renewal, and revocation of "VR" 
symbol stamps and certificates of authori- 
zation, the National Board Appeals Com- 
mittee procedures provide an affected "VR" 
Certificate of Authorization applicant the 
right of appeal, or to provide additional 
information that may affect the Committee's 
decision. 



1.7.2 JURISDICTIONAL 

PARTICIPATION 

The National Board member jurisdiction in 
which the "VR" organization is located is 
encouraged to participate in the review and 
demonstration of the applicant's quality system. 
The Jurisdiction may require participation in 
the review of the repair organization and the 
demonstration and acceptance of the repair 
organization's quality system manual. 



z i 



NATIONAL BDARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



1.7.3 



GENERAL RULES 



1.7.5.2 



ISSUANCE OF CERTIFICATE 



The general rules of the National Board "VR" 
certification program apply only to the repair 
of National Board capacity certified ASME 
Code Section I "V" stamped, Section IV "HV" 
marked, and Section VIII "UV" stamped pres- 
sure relief valves that: 

a) Have been in service or have been exposed 
to environmental or other conditions such 
that there is reason to question their ability 
to perform equivalent to the standards for 
new valves; or 

b) Any or all of the valve's external adjustment 
seals have been broken, opened, or other- 
wise disturbed, regardless of the valve's age 
or service status. 



1.7.4 



REPAIR OF NUCLEAR VALVES 



Provided that the requirements of Supplement 9 
and applicable requirements of these rules are 
met, the "VR" certificate may be extended to 
apply to the repair of any ASME Code Section 
III, Class 1 , 2, or 3, pressure relief devices that 
have been capacity certified by the National 
Board and have been in service, regardless of 
their intended function, in a nuclear system. 



1.7.5 



1.7.5.1 



ISSUANCE AND RENEWAL OF 
THE "VR" CERTIFICATE OF 
AUTHORIZATION 



GENERAL 



a) Repair organizations, manufacturers, as- 
semblers, or users that make repairs to the 
American Society of Mechanical Engineers 
(ASME) Code symbol, stamped or marked 
(as applicable), and The National Board 
of Boiler and Pressure Vessel inspectors 
(National Board) capacity certified pres- 
sure relief valves may apply to the National 
Board for a Certificate of Authorization to 
use the "VR" symbol. The National Board 
may at any time, through the NBIC Com- 
mittee, modify the regulations concerning 
the issuance and use of such valve repair 
symbol. All such modified regulations shall 
become binding upon holders of valid 
Valve Repair Certificates of Authorization. 

b) Authorization to use the "VR" stamp may be 
granted or withheld by the National Board 
in its absolute discretion. If authorization is 
granted and proper administrative fees paid, 
a Certificate of Authorization will be issued 
evidencing permission to use such a sym- 
bol, expiring on the triennial anniversary 
date. The certificate will be signed by the 
National Board Chairman of the National 
Board of Trustees, the Executive Director, 
or any other duly authorized officer. 

c) The certificate shall list the physical, per- 
manent address of record for the certificate 
holder's shop/plant. For field-only scopes, 
this address of record shown on the Certifi- 
cate of Authorization is where administra- 
tive, technical, and quality aspects of the 
business are controlled. 



Authorization to use the stamp bearing the of- 
ficial National Board "VR" symbol as shown 
in Section 5 of this Part, will be granted by the 
National Board pursuant to the provisions of the 
following administrative rules and procedures. 
Supplement 9 of this Part, provides rules for 
the repair of ASME Section III "NV" stamped 
pressure relief devices. 



1.7.5.3 RENEWAL OF CERTIFICATE 

The Certificate of Authorization is renewable 
every three (3) years subject to a review of 
the Quality System by a representative of 
the National Board, review and acceptance 
of the representative's report by the National 
Board, and successful completion of capacity 



22 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



tion mark may be stamped (low stress stamp) 
adjacent to welded joints made by the indi- 
vidual or the "R" Certificate Holder may keep 
a documented record of welded joints and the 
welders or welding operators used in making 
the joints. 



2.2.6 



WELDER'S CONTINUITY 



The performance qualification of a welder or 
welding operator shall be affected when one 
of the following conditions occur: 

a) When the welder or welding operator has 
not welded using a specific process dur- 
ing a period of six months or more, their 
qualifications for that process shall expire. 
The "R" Certificate Holder shall maintain a 

A07 welding continuity record and shall make 
the record available to the Inspector. The 
method of recording welding continuity 
and the record retention period shall be 
described in the "R" Certificate Holder's 
Quality System Manual. 

b) When there is specific reason to question 
their ability to make welds that meet the 
specification, the qualification which sup- 
ports the welding that is being performed 
shall be revoked. All other qualifications 
not questioned remain in effect. 



units or metric units may be used for all SWPSs A07 
in Table 2.3, but one system shall be used for 
application of the entire SWPS in accordance 
with the metric conversation table contained in 
the SWPS. The user may issue supplementary 
instructions as allowed by the SWPS. Standard 
Welding Procedures Specifications shall not be 
used in the same product joint together with the 
other Standard Welding Procedures Specifica- 
tions or other welding procedure specifications 
qualified by the organization. 

The AWS reaffirms SWPSs in accordance 
with ANSI procedures. When reaffirmation 
occurs without revision to the SWPS, the 
letter "R" is added to the SWPS designation 
following the year. Such designation is con- 
sidered to be identical with the previously 
published version and may be used pending 
incorporation herein, on the same basis as 
the version listed in Table 2.3. 



2.3 STANDARD WELDING 

PROCEDURE SPECIFICATIONS 

One or more (SWPSs) from Table 2.3 may be 
used as an alternative to one or more WPS 
documents qualified by the organization mak- 
ing the repair or alteration, provided the or- 
ganization accepts by certification (contained 
therein) full responsibility for the application of 
the SWPS in conformance with the application 
as stated in the SWPS. When using SWPS's, all 
variables listed on the standard welding pro- 
cedure are considered essential and, therefore, 
the repair organization cannot deviate, modify, 
amend, or revise any SWPS's. US Customary 



43 



NATIONAL BOARD INSPECTION CODE " PART 3 — REPAIRS AND ALTERATIONS 



Table 2.3 

Carbon Steel — (P1 Materials) 





SMAW — Shielded Metal Arc Welding 




Standard Welding Procedure Specification for Shielded Metal Arc Welding of Carbon 
Steel, (M-1/P-1 , Group 1 or 2), 3/1 6 in. (5 mm) through 3/4 in. (1 3 mm), in the As-Welded 
Condition, With Backing. 


B2. 1.001-90 

and 

B2. 1-1-001: 

90(R2006) 




Standard Welding Procedure Specification for Shielded Metal Arc Welding of Carbon Steel 
(M-1/P-1/S-1, Group 1 or 2), 1/8 in. (3.2 mm) through 1-1/2 in. (38 mm) Thick, E7018, As- 
Welded or PWHT Condition. 


B2.1 -1-01 6-94 

and 

B2.1-1-016-94R 




Standard Welding Procedure Specification for Shielded Metal Arc Welding of Carbon Steel 
(M-1/P-1/S-1, Group 1 or 2), 1/8 in. (3.2 mm) through 1-1/2 in. (38 mm) Thick, E6010, As- 
Welded or PWHT Condition. 


B2. 1-1-01 7-94 

and 

B2.1-1-017-94R 




Standard Welding Procedure Specification for Shielded Metal Arc Welding of Carbon Steel 
(M-1/P-1/S-1, Group 1 or 2), 1/8 in. (3.2 mm) through 1-1/2 in. (38 mm) Thick, E6010 
(Vertical Uphill) followed by E701 8, As-Welded or PWHT Condition. 


B2. 1-1-022-94 

and 

B2.1-1-022-94R 




Standard Welding Procedure Specification for Shielded Metal Arc Welding of Carbon Steel 
(M-1/P-1/S-1, Group 1 or 2), 1/8 in. (3.2 mm) through 1-1/2 in. (38 mm) Thick, E6010 
(Vertical Downhill) followed by E7018, As-Welded or PWHT Condition. 


B2.1 -1-026-94 

and 

B2.1-1-026-94R 


A08 


Standard Welding Procedure Specification for Shielded Metal Arc Welding of Carbon Steel 
(M-1/P-1/S-1, Group 1 or 2), 1/8 in. (3.2 mm) through 3/4 in. (19 mm) Thick, E6010 
(Vertical Downhill) followed by E7018, (Vertical Uphill) As-Welded Condition, Primarily 
Pipe Applications. 


B2.1 -1-201 -96, 
and B2. 1-1-201- 
96(R2007) 


A08 


Standard Welding Procedure Specification for Shielded Metal Arc Welding of Carbon Steel 
(M-1/P-1/S-1, Group 1 or 2), 1/8 in. (3.2 mm) through 3/4 in. (19 mm) thick, E6010 (Verti- 
cal Downhill) followed by E7018 (Vertical Uphill), As-Welded Condition, Primarily Pipe 
Applications. 


B2. 1-1-202- 
96(R2007) 


A08 


Standard Welding Procedure Specification for Shielded Metal Arc Welding of Carbon Steel 
(M-1/P-1/S-1, Group 1 or 2), 1/8 in. (3.2 mm) through 3/4 in. (19 mm) Thick, E6010 
(Vertical Uphill), As-Welded Condition, Primarily Pipe Applications. 


B2. 1-1-203-96 
and B2. 1-1 -203- 
96(R2007) 


A08 


Standard Welding Procedure Specification for Shielded Metal Arc Welding of Carbon 
Steel (M-1/P-1/S-1, Group 1 or 2), 1/8 in. (3.2 mm) through 3/4 in. (19 mm) Thick, E6010 
(Vertical downhill root with balance vertical uphill), As-Welded Condition, Primarily Pipe 
Applications. 


B2.1 -1-204-96 
and B2.1 -1-204- 
96(R2007) 


A08 


Standard Welding Procedure Specification for Shielded Metal Arc Welding of Carbon Steel 
(M-1/P-1/S-1, Group 1 or 2), 1/8 in. (3.2 mm) through 1-1/2 in. (38 mm) Thick, E6010 
(Vertical Uphill) followed by E7018 (Vertical Uphill), As-Welded or PWHT Condition, 
Primarily Pipe Applications. 


B2.1 -1-205-96 
and B2.1 -1-205- 
96(R2007) 


A08 


Standard Welding Procedure Specification for Shielded Metal Arc Welding of Carbon Steel 
(M-1/P-1/S-1, Group 1 or 2), 1/8 in. (3.2 mm) through 3/4 in. (19 mm) Thick, E6010 
(Vertical Downhill) followed by E701 8 (Vertical Uphill), As-Welded or PWHT Condition, 
Primarily Pipe Applications. 


B2. 1-1-206-96 
and B2. 1-1 -206- 
96(R2007) 



44 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



A08 


Standard Welding Procedure Specification for Shielded Metal Arc Welding of Carbon Steel 
(M-1/P-1/S-1, Group 1 or 2), 1/8 in. (3.2 mm) through 3/4 in. (19 mm) Thick, E701 8, As- 
Welded or PWHT Condition, Primarily Pipe Applications. 


B2.1 -1-208-96 


A08 


Standard Welding Procedure Specification for Shielded Metal Arc Welding of Carbon Steel 
(M-1/P-1/S-1, Group 1 or 2), 1/8 in. (3.2 mm) through1-1/2 in. (38 mm) Thick, E7018, As- 
Welded or PWHT Condition, Primarily Pipe Applications. 


B2. 1-1-208- 
96(R2007) 




GTAW — Gas Tungsten Arc Welding 


A08 


Standard Welding Procedure Specification for Gas Tungsten Arc Welding of Carbon Steel, 
(M-1/P-1, Group 1 or 2), 3/16 in. (5 mm) through 7/8 in. (22 mm) Thick, in the As-Welded 
Condition, With or Without Backing. 


B2. 1-002-90, 
B2.1-002- 
90(R2006) and 
B2.1-1-002-90R 




Standard Welding Procedure Specification for Gas Tungsten Arc Welding of Carbon Steel 
(M-1/P-1/S-1, Group 1 or 2), 1/8 in. (3.2 mm) through 3/4 in. (19 mm) Thick, ER70S-2, 
As-Welded or PWHT Condition, Primarily Pipe Application. 


B2.1 -1-207-96 


A08 


Standard Welding Procedure Specification for Gas Tungsten Arc Welding of Carbon Steel 
(M-1/P-1/S-1, Group 1 or 2), 1/8 in. (3.2 mm) through 1-1/2 in. (38 mm) Thick, ER70S-2, 
As-Welded or PWHT Condition, Primarily Pipe Application. 


B2. 1-1-207-96 
(R2007) 




Standard Welding Procedure Specification for Gas Tungsten Arc Welding (Consumable 
Insert) of Carbon Steel (M-1/P-1/S-1, Group 1 or 2), 1/8 in. (3.2 mm) through 3/4 in. 
(1 9 mm) Thick, INMsl and ER70S-2, As-Welded or PWHT Condition, Primarily Pipe 
Application. 


B2. 1-1-210-96 




Standard Welding Procedure Specification for Gas Tungsten Arc Welding with Consumable 
Insert Root of Carbon Steel (M-1/P-1/S-1, Group 1 or 2), 1/8 in. (3.2 mm) through 1-1/2 in. 
(38 mm) Thick, INMs-1, ER70S-2, As-Welded or PWHT Condition, Primarily Pipe 
Applications. 


B2. 1-1-210:2001 




FCAW — Flux Core Art Welding 




Standard Welding Procedure Specification for Self-Shielded Flux Cored Arc Welding of 
Carbon Steel (M-1/P-1/S-1, Group 1 or 2), 1/8 in. (3.2 mm) through 1-1/2 in. (38 mm) 
Thick, E71T-8, As-Welded Condition. 


B2.1 -1-01 8-94 

and 

B2.1-1.018-94R 




Standard Welding Procedure Specification for C02 Shielded Flux Cored Arc Welding of 
Carbon Steel (M-1/P-1/S-1, Group 1 or 2), 1/8 in. (3.2 mm) through 1-1/2 in. (38 mm) 
Thick, E70T-1 and E71T-1, As-Welded Condition. 


B2. 1-1-019-94 

and 

B2.1-1-019-94R 




Standard Welding Procedure Specification for 75% Ar/25% C02 Shielded Flux Cored Arc 
Welding of Carbon Steel (M-1/P-1/S-1, Group 1 or 2), 1/8 in. (3.2 mm) through 1-1/2 in. 
(38 mm) Thick, E70T-1M and E71T-1M, As-Welded or PWHT Condition. 


B2.1 -1-020-94 

and 

B2.1-1-020-94R 




Standard Welding Procedure for Self-Shielded Flux Cored Arc Welding of Carbon Steel 
(M-1/P-1/S-1, Group 1 or 2), 1/8 in. (3.2 mm) through 1/2 in. (13 mm) Thick, E71T-11, 
As-Welded Condition. 


B2.1-1 -027:1 995 

and 

B2. 1-1-027-1998 



45 



NATIONAL BOARD INSPECTION CODE * PART 3 



REPAIRS AND ALTERATIONS 



A07 Standard Welding Procedure Specification (SWPS) for Argon Plus 25% Carbon Dioxide 
Shielded Flux Cored Arc Welding of Carbon Steel (M-1/P-1/S-1, Croups 1 and 2), 1/8 in. 
(3.2 mm) through 1-1/2 in. (38 mm) Thick, E7XT-XM, As-Welded or PWHT Condition, 
Primarily Pipe Applications. 



CMAW - Gas Metal Arc Welding 



A07 Standard Welding Procedure Specification for Argon Plus 25% Carbon Dioxide Shielded 
Gas Metal Arc Welding (Short Circuiting Transfer Mode) followed by Argon Plus 2% 
Oxygen Shielded Gas Metal Arc Welding (Spray Transfer Mode) of Carbon Steel 
(M-1/P-1/S-1, Groups 1 and 2), 1/8 in. (3.2 mm) through 1-1/2 in. (38 mm) Thick, ER70S-3, 
Flat Position Only, As-Welded or PWHT Condition, Primarily Pipe Applications. 



B2. 1-1-234: 
2006 



A07 Standard Welding Procedure Specification for Argon Plus 2% Oxygen Shielded Gas Metal 
Arc Welding (Spray Transfer Mode) of Carbon Steel (M-1/P-1/S-1, Groups 1 and 2), 
1/8 in. (3.2 mm) through 1-1/2 in. (38 mm) Thick, ER70S-3, Flat Position Only, As-Welded 
or PWHT Condition, Primarily Pipe Applications. 



CTAW/SMAW Combination of Welding Processes 



Standard Welding Procedure Specification for Gas Tungsten Arc Welding Followed by 
Shielded Metal Arc Welding of Carbon Steel (M-1/P-1/S-1, Group 1 or 2), 1/8 in. (3.2 mm) 
through 1-1/2 in. (38 mm) Thick, ER70S-2 and E7018, As-Welded or PWHT Condition. 



B2. 1-1-233: 
2006 



B2. 1-1-235: 
2006 



B2. 1-1-021-94 

and 

B2.1-1-021-94R 



Standard Welding Procedure Specification for Gas Tungsten Arc Welding followed by 
Shielded Metal Arc Welding of Carbon Steel (M-1/P-1/S-1, Groups 1 or 2), 1/8 in. 
(3.2 mm) through 3/4 in. (1 9 mm) Thick, ER70S-2 and E701 8, As-Welded or PWHT 
Condition, Primarily Pipe Applications. 



B2.1 -1-209-96 



A08 



Standard Welding Procedure Specification for Gas Tungsten Arc Welding followed by 
Shielded Metal Arc Welding of Carbon Steel (M-1/P-1/S-1, Groups 1 or 2), 1/8 in. 
(3.2 mm) through 1-1/2 in. (38 mm) Thick, ER70S-2 and E7018, As-Welded or PWHT 
Condition, Primarily Pipe Applications. 



B2.1 -1-209-96 
(R2007) 



Standard Welding Procedure Specification for Gas Tungsten Arc Welding (Consumable 
Insert) Followed by Shielded Metal Arc Welding of Carbon Steel (M-1/P-1/S-1, Group 1 
or 2), 1/8 in. (3.2 mm) through 3/4 in. (19 mm) Thick, INMsl and E701 8, As-Welded or 
PWHT Condition, Primarily Pipe Applications. 



B2. 1-1 -21 1-96 



A07 



Standard Welding Procedure Specification for Gas Tungsten Arc Welding with Consumable 
Insert Root Followed by Shielded Metal Arc Welding of Carbon Steel (M-1/P-1/S-1, Group 
1 or 2), 1/8 in. (3.2 mm) through 1-1/2 in. (38 mm) Thick, INMs-1, ER70S-2, and E7018 
As-Welded or PWHT Condition, Primarily Pipe Applications. 



GMAW/FCAW - Combination of Welding Processes 



Standard Welding Procedure Specification for Argon Plus 25% Carbon Dioxide Shielded 
Gas Metal Arc Welding (Short Circuiting Transfer Mode) Followed by Argon Plus 25% 
Carbon Dioxide Shielded Flux Cored Arc Welding of Carbon Steel (m-1/P-1/S-1, Groups 1 
and 2), 1/8 in. (3.2 mm) through 1-1/2 in. (38 mm) Thick, ER70S-3 and EXT-X, As-Welded 
or PWHT Condition, Primarily Pipe Applications. 



B2. 1-1-211:2001 



B2.1 -1-232:2006 



4S 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



Austenitic Stainless Steel — (M8/P8/S8 Materials) 



A08 



SMAW — Shielded Metal Arc Welding 


Standard Welding Procedure Specification for Shielded Metal Arc Welding of Austenitic 
Stainless Steel (M-8/P-8/S-8, Croup 1), 1/8 in. (3.2 mm) through 1-1/2 in. (38 mm) Thick, 
As- Welded Condition. 


B2. 1-8-023-94 


Standard Welding Procedure Specification for Shielded Metal Arc Welding of Austenitic 
Stainless Steel (M-8/P-8/S-8, Croup 1), 1/8 in. (3.2 mm) through 1-1/2 in. (38 mm) Thick, 
E3XX-XX, As-Welded Condition, Primarily Pipe Application. 


B2. 1-8-213-97 
and B2. 1-8-213- 
96(R2007) 


GTAW — 'Gas Tungsten Are Welding ■ 


Standard Welding Procedure Specification for Gas Tungsten Arc Welding of Austenitic 
Stainless Steel (M-8/P-8/S-8, Croup 1), 1/8 in. (3.2 mm) through 1-1/2 in. (38 mm) Thick, 
As-Welded Condition. 


B2. 1-8-024-94 


Standard Welding Procedure Specification for Gas Tungsten Arc Welding of Austenitic 
Stainless Steel (M-8/P-8/S-8, Group 1), 1/16 in. (1.6 mm) through 1-1/2 in. (38 mm) Thick, 
ER3XX, As-Welded Condition, Primarily Plate and Structural Applications. 


B2. 1-8-024:2001 


Standard Welding Procedure Specification for Gas Tungsten Arc Welding of Austenitic 
Stainless Steel (M-8/P-8/S-8, Group 1 ), 1/1 6 in. (1 .6 mm) through 1 -1/2 in. (38 mm) Thick, 
ER3XX, As-Welded Condition, Primarily Pipe Applications. 


B2. 1-8-212-97 


Standard Welding Procedure Specification for Gas Tungsten Arc Welding of Austenitic 
Stainless Steel (M-8/P-8/S-8, Group 1), 1/16 in. (1.6 mm) through 1-1/2 in. (38 mm) thick, 
ER3XX, As-Welded Condition, Primarily Pipe Applications. 


B2. 1-8-212:2001 


Standard Welding Procedure Specification for Gas Tungsten Arc Welding With 
Consumable Insert Root of Austenitic Stainless Steel (M-8/P-8/S-8, Group 1), 1/8 in. 
(3.2 mm) through 1-1/2 in. (38 mm) Thick, IN3XX and ER3XX As-Welded Condition, 
Primarily Pipe Applications. 


B2. 1-8-215:1998 
B2.1 -8-21 5:2001 


Combination Processes GTAW/SMAW 


Standard Welding Procedure Specification for Gas Tungsten Arc Welding followed by 
Shielded Metal Arc Welding of Austenitic Stainless Steel (M-8/P-8/S-8, Group 1), 1/8 in. 
(3.2 mm) through 1-1/2 in. (38 mm) Thick, As-Welded Condition. 


B2. 1-8-025-94 


Standard Welding Procedure Specification for Gas Tungsten Arc Welding followed by 
Shielded Metal Arc Welding of Austenitic Stainless Steel (M-8/P-8/S-8, Group 1), 1/8 in. 
(3.2 mm) through 1-1/2 in. (38 mm) Thick, ER3XX and E3XX-XX, As-Welded Condition, 
Primarily Plate and Structural Applications. 


B2. 1-8-025:2001 


Standard Welding Procedure Specification for Gas Tungsten Arc Welding Followed by 
Shielded Metal Arc Welding of Austenitic Stainless Steel (M-8/P-8/S-8, Group 1), 1/8 in. 
(3.2 mm) through 1-1/2 in. (38 mm) Thick, ER3XX and E3XX-XX, As-Welded Condition, 
Primarily Pipe Applications. 


B2. 1-8-214-97 


Standard Welding Procedure Specification for Gas Tungsten Arc Welding Followed by 
Shielded Metal Arc Welding of Austenitic Stainless Steel (M-8/P-8/S-8, Group 1 ), 1/8 in. 
(3.2 mm) through 1-1/2 in. (38 mm) Thick, ER3XX and E3XX-XX, As-Welded Condition, 
Primarily Pipe Applications. 


B2.1 -8-21 4:2001 



4-V 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



Standard Welding Procedure Specification for Gas Tungsten Arc Welding With 
Consumable Insert Followed by Shielded Metal Arc Welding of Austenitic Stainless Steel 
(M-8/P-8/S-8, Croup 1), 1/8 in. (3.2 mm) through 1-1/2 in. (38 mm) thick, IN3XX, ER3XX, 
and E3XX-XX As-Welded Condition, Primarily Pipe Application. 



B2. 1-8-216-1998 



Standard Welding Procedure Specification for Gas Tungsten Arc Welding with Consumable 
Insert Root followed by Shielded Metal Arc Welding of Austenitic Stainless Steel 
(M-8/P-8/S-8, Group 1), 1/8 in. (3.2 mm) through 1-1/2 in. (38 mm) Thick, IN3XX, ER3XX, 
and E3XX-XX As-Welded Condition, Primarily Pipe Applications. 



B2. 1-8-21 6:2001 



Combination of Carbon Steel (P-1 Material) To Austenitic Stainless Steel (P-8 Material) 



SMAW — Shielded Metal Arc Welding 


Standard Welding Procedure Specifications for Shielded Metal Arc Welding of Carbon 
Steel (M-1/P-1/S-1, Groups 1 or 2) to Austenitic Stainless Steel (M-8/P-8/S-8, Group 1), 
1/8 in. (3.2 mm) through 1-1/2 in. (38 mm) Thick, E309(L)-15, -16, or -1 7, As-Welded 
Condition, Primarily Pipe Applications. 


82.1-1/8-228:2002 


GTAW — Gas Tungsten Arc Welding 


Standard Welding Procedure Specification for Gas Tungsten Arc Welding of Carbon 
Steel (M-1/P-1/S-1, Groups 1 or 2) to Austenitic Stainless Steel (M-8/P-8/S-8, Group 1), 
1/16 in. (1.6 mm) through 1-1/2 in. (38 mm) Thick, ER309(L), As-Welded Condition, 
Primarily Pipe Applications. 


B2. 1-1/8-227:2002 


Standard Welding Procedure Specifications for Gas Tungsten Arc Welding with 
Consumable Insert Root of Carbon Steel (M-1/P-1/S-1, Groups 1 or 2) to Austenitic 
Stainless Steel (M-8/P-8/S-8, Group 1), 1/16 in. (1.6 mm) through 1-1/2 in. (38 mm) 
Thick, IN309 and ER309(L), As-Welded Condition, Primarily Pipe Applications. 


B2. 1-1/8-230:2002 


GTAW/SMAW Combination of Welding Processes 


Standard Welding Procedure Specifications for Gas Tungsten Arc Welding followed by 
Shielded Metal Arc Welding of Carbon Steel (M-1/P-1/S-1, Groups 1 or 2) to Austenitic 
Stainless Steel (M-8/P-8/S-8, Group 1), 1/8 in. (3.2 mm) through 1-1/2 in. (38 mm) 
Thick, ER309(L) and E309(L)-1 5, -1 6, or -1 7, As-Welded Condition, Primarily Pipe 
Applications. 


B2. 1-1/8-229:2002 


Standard Welding Procedure Specifications for Gas Tungsten Arc Welding with 
Consumable Insert Root followed by Shielded Metal Arc Welding of Carbon Steel 
(M-1/P-1/S-1, Groups 1 or 2) to Austenitic Stainless Steel (M-8/P-8/S-8, Group 1), 
1/8 in. (3.2 mm) through 1-1/2 in. (38 mm) Thick, IN3009, ER309, and E309-15, -16, or 
-1 7 or IN309, ER309(L) and ER309(L)-1 5, -1 6, or -1 7, As-Welded Condition, Primarily 
Pipe Applications. 


B2. 1-1/8-231:2002 



Chromium Molybdenum Steel (M4/P4 and M5a/P5A Materials) 



SMAW — Shielded Metal Arc Welding 



Standard Welding Procedure Specifications for Shielded Metal Arc Welding of 
Chromium-Molybdenum Steel (M-4/P-4, Group 1 or 2), E8018-B2, 1/8 in. (3.2 mm) 
through 1-1/2 in. (38 mm) Thick, As-Welded Condition, 1/8 in. (3.2 mm) through 
1-1/2 in. (38 mm) Thick, PWHT Condition, Primarily Pipe Applications. 



B2.1 -4-21 8:1 999 



4B 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



Standard Welding Procedure Specifications for Shielded Metal Arc Welding of 
Chromium-Molybdenum Steel (M-5A/P-5A), E9018-B3, 1/8 in. (3.2 mm) through 
1-1/2 in. (38 mm) Thick, As-Welded Condition, 1/8 in. (3.2 mm) through 1-1/2 in. 
(38 mm) Thick, PWHT Condition, Primarily Pipe Applications. 


B2.1-5A-223:1999 


GTAW — Gas Tungsten Arc Welding 


Standard Welding Procedure Specifications for Gas Tungsten Arc Welding of 
Chromium-Molybdenum Steel (M-4/P-4, Group 1 or 2), ER80S-B2, 1/8 in. (3.2 mm) 
through 1-1/2 in. (38 mm) Thick, As-Welded Condition, 1/8 in. (3.2 mm) through 3/4 in. 
(19 mm) Thick, PWHT Condition, Primarily Pipe Applications. 


B2. 1-4-21 7:1999 


Standard Welding Procedure Specifications for Gas Tungsten Arc Welding (Consumable 
Insert Root) of Chromium-Molybdenum Steel (M-4/P-4, Group 1 or 2), E8018-B2, 
1/8 in. (3.2 mm) through 1-1/2 in. (38 mm) Thick, As-Welded Condition, 1/8 in. 
(3.2 mm) through 3/4 in. (19 mm) Thick, PWHT Condition, IN515 and ER80S-B2, 
Primarily Pipe Applications. 


B2.1 -4-220:1 999 


Standard Welding Procedure Specifications for Gas Tungsten Arc Welding of 
Chromium-Molybdenum Steel (M-5A/P-5A), ER90S-B3, 1/8 in. (3.2 mm) through 
1-1/2 in. (38 mm) Thick, As-Welded Condition, 1/8 in. (3.2 mm) through 3/4 in. 
(19 mm) Thick, PWHT Condition, Primarily Pipe Applications. 


B2.1-5A-222:1999 


Standard Welding Procedure Specifications for Gas Tungsten Arc Welding (Consumable 
Insert Root) of Chromium-Molybdenum Steel (M-5A/P-5A), 1/8 in. (3.2 mm) through 
1-1/2 in. (38 mm) Thick, As-Welded Condition, 1/8 in. (3.2 mm) through 3/4 in. 
(19 mm) Thick, PWHT Condition, IN521 and ER90S-B3, Primarily Pipe Applications. 


B2.1-5A-225:1999 


Chromium-Molybdenum Steel Processes GTAW/SMAW 


Standard Welding Procedure Specifications for Gas Tungsten Arc Welding (Consumable 
Insert Root) followed by Shielded Metal Arc Welding of Chromium-Molybdenum Steel 
(M-4/P-4, Group 1 or 2), 1/8 in. (3.2 mm) through 1-1/2 in. (38 mm) Thick, As-Welded 
Condition, 1/8 in. (3.2 mm) through 1-1/2 in. (38 mm) Thick, PWHT Condition, IN515, 
ER80S-B2, and E8018-B2, Primarily Pipe Applications. 


B2.1 -4-221:1 999 


Standard Welding Procedure Specifications for Gas Tungsten Arc Welded followed by 
Shielded Metal Arc Welding of Chromium-Molybdenum Steel (M-5A/P-5A), 1/8 in. 
(3.2 mm) through 1-1/2 in. (38 mm) Thick, As-Welded Condition, 1/8 in. (3.2 mm) 
through 1-1/2 in. (38 mm) Thick, PWHT Condition, ER90S-B3 and E9018-B3, Primarily 
■Pipe Applications. 


B2.1-5A-224:1999 


Standard Welding Procedure Specifications for Gas Tungsten Arc Welding (Consumable 
Insert Root) followed by Shielded Metal Arc Welding of Chromium-Molybdenum Steel 
(M-5A/P-5A), 1/8 in. (3.2 mm) through 1-1/2 in. (38 mm) Thick, As-Welded Condition, 
1/8 in. (3.2 mm) through 1-1/2 in. (38 mm) Thick, PWHT Condition, IN521, ER90S-B3, 
and E9018-B3, Primarily Pipe Applications. 


B2.1-5A-226:1999 


Standard Welding Procedure Specifications (SWPS) for Gas Tungsten Arc Welded fol- 
lowed by Shielded Metal Arc Welding of Chromium-Molybdenum Steel (M-4A/P-4, 
Group 1 or 2), 1/8 in. (3.2 mm) through 1/2 in. (13 mm) Thick, As-Welded Condition, 
1/8 in. (3.2 mm) through 1-1/2 in. (38 mm) Thick, PWHT Condition, ER80S-B2 and E- 
018-B2, Primarily Pipe Applications. 


B2.1 -4-21 9:1 999 



49 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



2.4 



AWS REFERENCE STANDARDS 



The fol lowing AWS Standards have been adopt- 
ed by the NBIC for use as referenced below: 

a) AWS B2.1 Specification for Welding Pro- 
cedure and Performance Qualification 

b) AWS B2.1 BMG — Base Metal Grouping 
for Welding Procedure and Performance 
Qualification 



2.5 



2.5.1 



HEAT TREATMENT 



PREHEATING 



Preheating may be employed during weld- 
ing to assist in completion of the welded 
joint. The need for and the temperature 
of preheat are dependent on a number of 
factors such as chemical analysis, degree 



of restraint of the items being joined, mate- 
rial thickness, and mechanical properties. 
The welding procedure specification for 
the material being welded shall specify the 
preheat temperature requirements. 

b) See minimum temperatures for preheating 
given in Table 2.5.1 as a general guide. It is 
cautioned that the preheating temperatures 
listed do not necessarily ensure satisfactory 
completion of the welded joint. Require- 
ments for individual materials within the 
P-Number listing may have preheating 
requirements more or less restrictive than 
this general guide. When reference is made 
in this section to materials by the ASME 
designation, P-Number and Group Num- 
ber, the suggestions of this Section apply 
to the applicable materials of the original 
code of construction, either ASME or other, 
which conform by chemical composition 
and mechanical properties to ASME materi- 
als having the ASME P-Number and Group 
Number designations. 



Table 2.5.1 

Minimum Temperatures for Preheating 



Thicknesses referenced are nominal at the weld for the parts to be joined. 


a) P-No. 1 Group Nos. 1, 2, and 3 


1 ) 1 75°F (79°C) for material that has both a specified maxi- 

mum carbon content in excess of 0.30% and a thickness 
at the joint in excess of 1 in. 

2) 50T (10°C) for all other materials in this P-Number. 


b) P-No. 3 Group Nos. 1, 2, and 3 


1 ) 1 75°F (79°C) for material that has either a specified mini- 

mum tensile strength in excess of 70,000 psi (480 MPa) 
or a thickness at the joint in excess of 5/8 in. (1 6 mm). 

2) 50°F (1 0°C) for all other materials in this P-Number. 


c) P-No. 4 Group Nos. 1 and 2 


1 ) 250°F (1 20°C) for material that has either a specified mini- 

mum tensile strength in excess of 60,000 psi (410 MPa) 
or a thickness at the joint in excess of 1/2 in. (1 3 mm). 

2) 50°F (1 0°C) for all other materials in this P-Number. 



50 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



d) P-No. 5A Group 1 and 5B, Group 1 


1) 400°F (205°C) for material that has either a specified mini- 

mum tensile strength in excess of 60,000 psi (410 MPa) 
or has both a specified minimum chromium content 
above 6.0% and thickness at the joint in excess of 1/2 in. 
(13 mm). 

2) 300°F (150°C)forall other materials in this P-Number. 


e) P-No. 6 Group Nos. 1, 2, and 3 


400°F (205°C) 


f) P-No. 7 Group Nos. 1 and 2 


None 


g) P-No. 8 Group Nos. 1 and 2 


None 


h) P-No. 9 Croup 


1 ) 250°F (1 20°C) for P-9A Gr. 1 materials 

2) 300°F (1 50°C) for P-9B Gr. 1 materials 


i) P-No. 10 Croup 


1 ) 1 75°F (79'C) for P-1 0A Gr. 1 materials 

2) 250°F (120°C) for P-1 0B Gr. 2 materials 

3) 1 75°F (79°C) for P-1 0C Gr. 3 materials 

4) 250°F (120°C) for P-1 OF Gr. 6 materials 

5) For P-10C Gr. 3 materials, preheat is neither required nor 

prohibited, and consideration shall be given to the limita- 
tion of interpass temperature for various thicknesses to 
avoid detrimental effects on the mechanical properties of 
heat treated material. 

6) For P-1 0D Gr. 4 and P-1 0E Gr. 5 materials, 300°F (1 50°C) 

with interpass temperature maintained between 350°F 
and450°F(175°Cand230°C). 


j) P-No. 1 1 Group 


1) P-1 1 A Group 

Group 1 - None (Note 1) 

Group 2 - Same as for P-No. 5 (Note 1 ) 

Group 3 - Same as for P-No. 5 (Note 1 ) 

Croup4-250*F(120°C) 

2) P-1 1B Group 

Group 1 - Same as for P-No. 3 (Note 1 ) 
Group 2 - Same as for P-No. 3 (Note 1) 
Group 3 - Same as for P-No. 3 (Note 1) 
Group 4 - Same as for P-No. 3 (Note 1 ) 
Group 5 - Same as for P-No. 3 (Note 1 ) 
Croup 6 - Same as for P-No. 5 (Note 1 ) 
Group 7 - Same as for P-No. 5 (Note 1 ) 


Note 1 : Consideration shall be given to the limitation of interpass temperature for various thicknesses to avoid 
detrimental effects on the mechanical properties of heat treated materials. 



51 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



2.5.2 POSTWELD HEAT TREATMENT 

(PWHT) 

a) Postweld heat treatment shall be per- 
formed as required by the original code of 

A07 construction, the construction standard or 
code selected in accordance with a written 
procedure. The procedure shall contain the 
parameters for postweld heat treatment. 

b) When it is impractical or detrimental to 
postweld heat treat (PWHT) the entire item 
or band around the item, the following lo- 
cal PWHT method may be performed on 
spherical or cylindrical pressure-retaining 
items using the time and temperature 
parameters in the original code of con- 

A09 struction and in accordance with a written 
A07 procedure acceptable to the Inspector and, 
when required, by the Jurisdiction. 

1) Heat a local area around the nozzle, 
welded attachment, or repair area such 
that the area is brought up uniformly 
to the required PWHT temperature. 
The application of local PWHT should 
be performed with controlled heating 
methods, such as induction or electric 
resistance heaters, and employing ther- 
A07 mocouples to monitor PWHT tempera- 

ture. The SB shall extend tangential ly 
and radially from the edge of the nozzle 
wall, or attachment weld or repair area 
equally by a minimum distance as de- 
fined by the thickness of the shell, t or 
2 in. (50 mm), whichever is less. 

A07 Soak Band (SB) — this is the region 

on the spherical or cylindrical shell 
that will be heated uniformly to the 
required PWHT temperature. This band 
encompasses a circular region in the 
tangential and radial directions starting 
from the edge of a welded nozzle, or 
repair area or welded attachment that 
will be subjected to PWHT. 

A07 2) The length of the HB shall consist of 
the SB distance plus 4VR*t. In no case 
shall the distance of the HBthat extends 
beyond the edge of the nozzle weld, 



attachment weld or repair area be less 
than 5VR*t. 

Heating Band (HB) - this is the region A07 
that encompasses the application of 
heat for PWHT and is defined in length 
by the equation (SB+4VR*t), where R 
is the outer radius of the spherical or 
cylindrical shell in inches (mm), and t 
is equal to the nominal thickness of the 
spherical or cylindrical shell in inches 
(mm). 

3) The CCB shall be kept as low as pos- A07 
sible in all directions to avoid harm- 
ful temperature gradients adjacent to A07 
nozzles or geometric discontinuities. 

Gradient Control Band (GCB) - this is A07 
the region that encompasses the SB, 
HB and extends beyond the edge of the 
HB. 

4) For PWHT of nozzle welds, repair 
welds, and external attachment welds 
on smooth spherical shells, heads, 
and cylindrical shells, the temperature 
differential within the GCB measured 
at the outside edge of the SB and the 
temperature measured at the outside 
edge of the HB shall not exceed one- A07 
half (1/2) of the peak soak PWHT tem- 
perature. 

5) The term t, or definition of thickness for 
calculating the holding time, for local 
PWHT shall be the nominal thickness 
of either a full penetration weld, or the 
groove weld depth of a partial penetra- 
tion repair weld. If a fillet weld is used 
in combination with a groove weld, the 
nominal thickness for PWHT shall be 

the depth of the groove weld. A07 



2.5.3 ALTERNATIVE WELDING 

METHODS WITHOUT POST- 
WELD HEAT TREATMENT 

a) Under certain conditions, postweld heat 
treatment, in accordance with the original 



52 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



code of construction, may be inadvisable 
or impractical. In such instances, the fol- 
lowing alternative methods may be used. 

b) Competent technical advice shall be ob- 
tained from the manufacturer of the pres- 
sure-retaining item or from another quali- 
fied source, such advice being especially 
necessary if the alternative is to be used in 
highly stressed areas, if service conditions 
are conducive to stress corrosion cracking, 
if materials are subject to hydrogen embrit- 
tlement, or are operating at temperatures in 
the creep range, or if the alternative is being 
considered for "on-stream" repairs or "hot 
tapping" on piping systems. Selection of the 
welding method used shall be based on the 
rules of the original code of construction 
together with the above mentioned advice 
concerning the adequacy of the weld in 
the as-welded condition at operating and 
pressure test conditions. 

c) When reference is made in this Section to 
materials by the ASME designation, P-Num- 
ber and Group Number, the requirements 
of this Section apply to the applicable 
materials of the original code of construc- 
tion, either ASME or other, which conform 
by chemical composition and mechanical 
properties to the ASME P-Number and 
Group Number designations. 

d) The detailed welding methods listed in 
the following subsections may be used as 
an alternative to postweld heat treatment 
(PVVHT). Subsection 2.5.3.1 is a method 
in which the welding procedure requires 
an elevation of the preheat temperature. In 
contrast, 2.5.3.2 thru 2.5.3.5, are methods 
in which the welding procedure requires 
the use of a temper-bead welding tech- 

A09 nique. In 2.5.3.5 is a method in which the 
welding procedure used for joining dissimi- 
lar materials requires either an elevation of 
the preheat temperature or a temper-bead 
welding technique, depending on the 
chemical composition of the base metal 
that is joined to an austenitic steel. Temper- 
bead welding procedure nomenclature is 
defined in Section IX of the ASME Boiler 



and Pressure Vessel Code. Typically, this 
technique minimizes heat input of the 
initial beads, thus limiting heat beyond the 
weld heat-affected zone (HAZ) of the base 
metal. Heat input shall be increased for 
successive beads in accordance with the 
rules of QVV-290 for temper bead welding 
in Section IX of the ASME Boiler and Pres- 
sure Vessel Code. The welding procedure 
and welder performance qualifications 
shall, in all cases, be in accordance with 
the requirements of the latest edition and 
addenda of Section IX of the ASME Boiler 
and Pressure Vessel Code. 

e) Nondestructive Examination of Welds A09 

1 ) Prior to welding, the area prepared for 
welding shall be examined using either 
the magnetic particle (MT) or the liquid 
penetrant (PT) examination method to 
determine that no defects exist. After 
the finished weld has reached ambient 
temperature, the weld shall be exam- 
ined again by either of the above meth- 
ods to determine that no defects exist 
using acceptance standards acceptable 
to the Inspector or original Code of 
Construction. In addition, welds greater 
than 3/8 in. (9.6 mm) deep or welds 
in a boiler, pressure vessel, or piping 
system that were originally required 
to be radiographed by the rules of the 
original Code of Construction, shall be 
radiographically examined. In situa- 
tions where it is not practical to perform 
radiography, the accessible surfaces 
of each nonradiographed repair weld 
shall be fully examined using the MT 
or PT method to determine that no 
defects exist and the maximum allow- 
able working pressure and/or allowable 
temperature shall be re-evaluated to 
the satisfaction of the jurisdiction at the 
location of installation. 

f) Methods that may be used as alternatives 
to postweld heat treatment are described 
in the following subsections. 



53 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



2.5.3.1 



WELDING METHOD 1 



When using this method, the following is re- 
quired: 

a) This method may be used when the ap- 
plicable rules of the original code of con- 
struction did not require notch toughness 
testing. 

b) The materials shall be limited to P-No. 1, 
Groups 1 , 2, and 3 and to P-No. 3, Groups 
1 and 2 (excluding Mn-Mo steels in Group 
2), as permitted for welded construction by 
the applicable rules of the original code of 
construction. 

c) The welding shall be limited to the shielded 
metal-arc welding (SMAW), gas metal-arc 
welding (GMAW), fluxcored arc welding 
(FCAW), and gas tungsten-arc welding 
(GTAW) processes. 

d) The welders and welding procedures speci- 
fications shall be qualified in accordance 
with the applicable rules of the original 
code of construction, except that no post- 
weld heat treatment shall be appl ied to the 
test coupon. 

e) The weld area shall be preheated and main- 
tained at a minimum temperature of 300T 
(1 49°C) during welding. The 300°F (1 49°C) 
temperature shall be checked to assure that 
4 in. (102 mm) of the material or four times 
the material thickness (whichever is greater) 
on each side of the groove (or full thickness 
of joint for a groove weld) is maintained at 
the minimum temperature during welding. 
The maximum interpass temperature shall 
not exceed 450°F (230°C). When the weld 
does not penetrate through the full thick- 
ness of the material, the minimum preheat 
and maximum interpass temperatures need 
only be maintained at a distance of 4 in. 
(102 mm) or four times the depth of the 
repair weld, whichever is greater, on each 
side of the joint. 



2.5.3.2 WELDING METHOD 2 

When using this method, the following is re- 
quired: 

a) This method shall be used when the ap- 
plicable rules of the original code of con- 
struction required notch toughness testing 
or shall be used when the applicable rules 
of the original code of construction did not 
require notch toughness testing provided 
the adequacy of the notch toughness of the 
weld, including the heat-affected zone, in 
the as-welded condition at operating and 
pressure test conditions is verified. 

b) The materials shall be limited to carbon 
and low alloy steels permitted for welded 
construction by the applicable rules of the 
original code of construction, including those 
materials conforming to any of the following 
ASME P-No. designations: P-No. 1, Groups 
1 ,2, and 3, P-No. 3, Groups 1 , 2, and 3, P-No. 
4, P-No. 5A, P-No. 9A, P-No. 10A, P-No. 
1 0B, P-No. 1 0C, P-No. 1 1 A, or P-No. 1 1 B. 

c) The welding shall be limited to the Shielded 
Metal-Arc Welding (SMAW), Gas Metal-Arc 
Welding (GMAW), Fluxcored Arc Welding 
(FCAW), and Gas Tungsten-Arc Welding 
(GTAW) processes. 

d) The welding procedures specifications shall 
be qualified in accordance with the temper 
bead procedure qualification requirements 
in QW-290 of Section IX of the ASME Boiler 
and Pressure Vessel Code, and shall include 
the following additional requirements: 

1) For P-No. 1 Groups 1, 2, and 3 and P- 
No. 3 Groups 1, 2, and 3, the minimum 
preheat temperature shall be 350°F 
(1 77°C), and the maximum interpass 
shall be450°F(232°C). 

2) For P-No. 9A, P-No. 10A, P-No. 10B, 
P-No. 1 0C, P-No. 1 1 A, or P-No. 1 1 B, 
the minimum preheat and interpass 
temperature requirements shall be 
in accordance with the guidelines in 
2.5.1. 



54 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



3) For P-No. 4 and P-No. 5A materials, 
the minimum preheat, interpass tem- 
perature, and technique shall be in 
accordance with 2.5.3.4. The repair 
depth for temper bead repairs to P-No. 
4 and P-No. 5A materials shall be in 
accordance with the requirements of 
2.5.3.4(a) . 

e) The test material for the welding procedure 
qualification shall be of the same mate- 
rial specification (including specification 
type, grade, class, and condition of heat 
treatment) as the material being repaired. 
In the event that the notch toughness of 
the material to be repaired is unknown, 
evidence from tests of that material or from 
another acceptable source (see 2.5.3) may 
be used for the base metal notch tough- 
ness when qualifying the WPS as required 
in 2.5.3.2(h). In the event that the original 
material specification is obsolete, the test 
material used should conform as closely as 
possible to the original material used for 
construction based on nominal composi- 
tion and carbon equivalent (IIW Formula)/ 
but in no case shall the material be lower 
in strength. 

f) The qualification thickness for the test plates 
and repair groove depths shall be in accor- 

A09 dance with Section IX of the ASME Boiler 
and Pressure Vessel Code. 

g) The organization making the repair shall 
include, when qualifying its WPS; sufficient 
tests to determine that the notch toughness 
of the weld metal and the heat-affected 
zone of the base metal in the "as-welded" 
condition is adequate at the minimum 
operating and pressure test temperatures 
(including start-up and shutdown). If for 
reasons of corrosion resistance, special 
hardness limits are necessary, such limits 
shall be included when qualifying the 
WPS. 



h) Notch toughness shall be determined and 
evaluated by Charpy impact tests in accor- 
dance with the provisions of the original 
code of construction at the temperature 
determined in accordance with 2.5.3.2(d). 
Exemptions from impact testing described 
in the original code of construction are not 
applicable. 

i) For the welding process in 2.5.3.2(c), use 
only electrodes and filler metals that are 
classified by the filler metal specification 
with a diffusible-hydrogen designator of 
H8 or lower. When shielding gases are 
used with a process, the gas shall exhibit a 
dew point that is below -60°F (-50°C). Sur- 
faces on which welding will be done shall 
be maintained in a dry condition during 
welding and be free of rust, mill scale, and 
hydrogen producing contaminants such as 
oil, grease, and other organic materials. 

j) After the weld has been deposited flush 
with the base metal, a surface temper re- 
inforcing weld layer shall be applied. 

k) For welds made by SMAW and FCAW, 
after completion of welding and without 
allowing the weldment to cool below the 
minimum preheat temperature, the tem- 
perature of the weldment shal I be raised to 
a temperature of 450°F (232°C) minimum 
for a minimum period of two hours. This 
hydrogen bake-out treatment may be omit- 
ted provided the electrode used is classi- 
fied by the filler metal manufacturer with a 
diffusible-hydrogen designator of H4 (e.g., 
E7018-H4). 

I) After the finished repair weld has cooled 
to ambient temperature, the surface temper 
reinforcing layer shall be removed sub- 
stantially flush with the surface of the base 
material. 



2.5.3.3 



WELDING METHOD 3 



7 The IIW Carbon Equivalent Formula is CE= C+ Mn/6 + 
(Cr+Mo+V)/5 + (Ni+Cu)/15. Elements are expressed in Weight 
Percent Amounts. 



When using this method, the following is re- 
quired: 



55 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



a) This method may be used when the applica- 
ble rules of the original code of construction 
did not require notch toughness testing. 

b) The materials shall be limited to any P-No. 1 
or P-No. 3 material as permitted for welded 
construction by the applicable rules of the 
original code of construction. 

c) The welding shall be limited to the SMAW, 
FCAW, and GTAW processes. 

d) The test material for the welding procedure 
qualification shall be of the same P-No. 
and Croup No. as the base material speci- 
fication of the repair. In the event that the 
original material specification is obsolete, 
the test material used should conform to the 
nominal composition and carbon equiva- 
lent (IIW Formula) 8 as the material being 
repaired, but in no case shall the material 
be lower in strength. 

e) If for reasons of corrosion resistance, special 
hardness limits are necessary, such limits shall 
be included when qualifying the WPS. 

f) The qualification thickness for the test plates 
and repair groove depths shall be in accor- 
dance with Section IX of the ASME Boiler 
and Pressure Vessel Code 

g) The WPS shall be qualified in accordance 
with the temper bead procedure qualifica- 
tion requirements in QW-290 of Section 
IX of the ASME Boiler and Pressure Vessel 
Code, and shall include the following ad- 
ditional requirements: 

1 ) The minimum preheat temperature for 
welding shall be 350°F (1 77° C) and the 
maximum interpass temperature shall 
be450°F(232°C). 

2) For the welding processes in 2.5.3.3(c), 
only electrodes or filler metals that are 
classified by the filler metal specifica- 



tion with a diffusible-hydrogen designa- 
tor of H8 or lower may be used. When 
shielding gases are used with a process, 
the gas shall exhibit a dew point that is 
below -60°F (-50°C). Surfaces on which 
welding will be done shall be maintained 
in a dry condition during welding and be 
free of rust, mill scale, and hydrogen pro- 
ducing contaminants such as oil, grease, 
and other organic materials. 

3) After completion of welding using 
SMAW and without allowing the 
weldment to cool below the minimum 
preheat temperature, the temperature 
of the weldment shall be raised to a 
temperature of450°F(232°C) minimum 
for a minimum period of two hours. This 
hydrogen bake-out treatment may be 
omitted, provided the electrode used 
is classified by the filler metal manu- 
facturer with a diffusible-hydrogen 
designator of H4 (e.g., E701 8-H4). 

4) After the finished repair weld has 
cooled to ambient temperature, the 
final temper bead reinforcement layer 
shall be removed substantially flush 
with the surface of the base material. 



2.5.3.4 WELDING METHOD 4 

When using this method, the following is re- 
quired: 

a) This method is limited to repair welds in 
pressure-retaining items containing defects 
not penetrating through the full thickness 
for which the applicable rules of the origi- 
nal code of construction did not require 
notch toughness testing. 

b) The materials shall be limited to P-No. 4, 
Groups 1 and 2, and P-No. 5A steels as 
permitted for welded construction by the 
applicable rules of the original code of 
construction. 



8 The IIW Carbon Equivalent Formula is CE= C+ Mn/6 + 
(Cr+Mo+V)/5 + (Ni+Cu)/1 5. Elements are expressed in Weight 
Percent Amounts. 



56 



The welding shall be limited to the SMAW, 
FCAW, GMAW or GTAW processes using 



NATIONAL BPARD INSPECTION CODE * PART 3 



REPAIRS AND ALTERATIONS 



A08 low-hydrogen electrodes and filler metals 
classified by the filler metal specification 
with a diffusible-hydrogen designator of 
H8 or lower, and suitably controlled by 
maintenance procedures to avoid contami- 
nation by hydrogen producing sources. The 
surface of the metal prepared for welding 
shall be free of contaminants. 

d) The test material for the welding procedure 
qualification shall be of the same P-No. and 
Group No. as the original material specifi- 
cation for the repair. In the event that the 
original material specification is obsolete, 
the test material used shall conform to the 
nominal composition and carbon equiva- 
lent (IIW formula) 9 as the original material 
used for construction, and in no case shall 
the material be lower in strength. 

e) If for reasons of corrosion resistance, spe- 
cial hardness limits are necessary, such 
limits shall be included when qualifying 
the WPS. 



A09 



A08 



f) The qualification thickness for the test plates 
and repair groove depths shall be in accor- 
dance with Section IX of the ASME Boiler 
and Pressure Vessel Code 

The welding procedures (WPS) shall be 
qualified in accordance with the temper 
bead procedure qualification requirements 
in QW-290 of Section \Xof the ASME Boiler 
and PressureVessel Code, and shall include 
the following additional requirements: 

1) The minimum preheat temperature 
for welding shall be 300°F (1 50°C) for 
P-No. 4 material and 400°F (200°C) for 
P-No. 5A material. The preheat tem- 
perature shall be checked to ensure that 
4 in. (102mm) of the material or four 
times the material thickness (whichever 
is greater) on each side of the groove 
(or full thickness of joint for a groove 



9 The IIW Carbon Equivalent Formula is CE=C+ Mn/6 + 
(Cr+Mo+V)/5 + (Ni+Cu)/15. Elements are expressed in Weight 
Percent Amounts 



weld) is maintained at the minimum 
temperature during welding. The in- 
terpass temperature shall not exceed 
800°F (430°C). When the weld does not 
penetrate through the full thickness of 
the material, the minimum preheat and 
maximum interpass temperature need 
only be maintained for 4 in. (102mm) or 
four times the depth of the repair weld 
(whichever is greater) on each side of 
the joint. 

2) For the welding processes in 2.5.3.4(c), 
use only electrodes or filler metals that 
are classified by the filler metal specifi- 
cation with a diffusible-hydrogen des- 
ignator of H8 or lower. When shielding 
gases are used with a process, the gas 
shall exhibit a dew point that is below 
-60°F (-50°C). Surfaces on which weld- 
ing will be done shall be maintained in 
a dry condition during welding and be 
free of rust, mill scale, and hydrogen 
producing contaminants, such as oil, 
grease, and other organic materials. 

3) After the weld has been deposited flush 
with the base metal, a surface temper re- 
inforcing weld layer shall be applied. 

4) For welds made by the SMAW and A08 
FCAW processes, after completion 

of welding and without allowing the 
weldment to cool below the minimum 
preheat temperature, the temperature of 
the weldment shall be raised to 450°F 
(232°C) minimum for a minimum period 
of two hours. This hydrogen bake-out 
treatment may be omitted, provided the 
electrode used is classified by the filler 
metal manufacturer with a diffusible- 
hydrogen designator of H4 (e.g., E7018 
H4). 

5) After the finished repair weld has 
cooled to ambient temperature, the 
surface temper reinforcing weld layer 
shall be removed substantially flush 
with the surface of the base metal (and 
for a fillet weld to the required size and 
suitable contour of the toes). 



57 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



2.5.3.5 



WELDING METHOD 5 



When using this method, the following is re- 
quired: 

a) This welding method may be used when 
the applicable rules of the original code of 
construction or the construction standard or 
code selected permit joining dissimilar ma- 
terials used in pressure-retaining items. 

b) The materials shall be limited to ASME P- 
No. 1 , Groups 1 , 2, and 3, P-No. 3, Groups 
1,2, and 3, P-No. 4, P-No. 5A, P-No. 9A, 
P-No. 10A, P-No. 10B, P-No. 10C, P-No. 
1 1 A, P-No. 1 1 B joined to either P-No. 8, P- 
No. 42, P-No. 43, or P-No. 45, as permitted 
for welded construction by the applicable 
rules of the original code of construction. 

c) The welding shall be limited to the SMAW, 
FCAW, GMAW and machine or automatic 
GTAW processes. The filler metal used 
for joining the dissimilar materials shall 
be either A-No 8 or Nickel-Chrome alloy 
classification (F-No 43). When selecting a 
filler metal for dissimilar metal weld joints, 
determine if the weld joint will be exposed 
to elevated temperature service. A-No 8 
filler metals exposed to service tempera- 
tures greater than 800°F (427°C) will exhibit 
reduced creep life along the fusion zone of 
the ferritic material due to carbon diffusion. 
Instead, a low hydrogen, Nickel-Chromium 
alloy classification filler metal shall be used 
for dissimilar weld joints exposed to service 
temperatures at or above 800°F (427°C). 

d) The WPS shall be qualified in accordance 
with the temper bead rules of QW-290 in 
Section IX of the ASME Boiler and Pressure 
Vessel Code. 



e) If the original code of construction did not 
require notch toughness testing, qualifi- 
cation of welding procedures (WPS) for 
joining ASME P-No. 1, P-No. 3 ferritic 
materials to either P-No. 8, P-No. 42, P-No. 
43, or P-No. 45 materials shall be in accor- 
dance with requirements in either 2.5.3.1, 
Welding Method 1 or in 2.5.3.3, Welding 
Method 3. 

f) If the original code of construction did not 
require notch toughness testing, qualifica- 
tion of welding procedures (WPS) for join- 
ing ASME P-No. 4, P-No. 5A ferritic materi- 
als to either P-No. 8, P-No. 42, P-No. 43, 
P-No. 45 materials shall be in accordance 
with the requirements in 2.5.3.4, Welding 
Method 4. 

g) If the original code of construction required 
notch toughness testing, qualification of 
welding procedures (WPS) for joining fer- 
ritic materials to either P-No. 8, P-No. 42, 
P-No. 43, or P-No. 45 materials shall be 
in accordance with the requirements in 
2.5.3.2, Welding Method 2. 



58 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



original code of construction. The supplier 
or manufacturer shall certify that the mate- 
rial and fabrication are in accordance with 
the original code of construction. This certi- 
fication shall be supplied in the form of bills 
of material and drawings with statement 
of certification. Examples include boiler 
furnace wall or floor panel assemblies, 
prefabricated openings in boiler furnace 
walls, such as burner openings, air ports, 
inspection openings, or sootblower open- 
ings. 

c) When ASME is the original code of con- 
struction, replacement parts subject to 
internal or external pressure fabricated by 
welding, which require inspection by an 
Authorized Inspector shall be fabricated 
by an organization having an appropriate 
ASME Certificate of Authorization. The item 
shall be inspected and stamped as required 
by the applicable section of the ASME 
Code. A completed ASME Manufacturer's 
Partial Data Report shall be supplied by the 
manufacturer. 

A08 The "R" certificate holder using replace- 
ment parts fabricated and certified to an 
ASME code edition and addenda different 
from that used for the original construction 
shall consider and seek technical advice, 
where appropriate, for change or conflicts 
in design, materials, welding, heat treat- 
ment, examinations and tests to assure a 
safe repair/alteration is performed. Note 
that work once classified as a repair could 
now be considered an alteration. 

d) When the original code of construction is 
other than ASME, replacement parts subject 
to internal or external pressure, fabricated 
by welding shall be manufactured by an 
organization certified as required by the 
original code of construction. The item shall 
be inspected and stamped as required by 
the original code of construction. Certifica- 
tion to the original code of construction, 
as required by the original code of con- 
struction or equivalent, shall be supplied 
with the item. When this is not possible or 



practicable, the organization fabricating A08 
the part shall have a National Board "R" 
Certificate of Authorization; replacement 
parts shall be documented on Form R-3 and 
the "R" symbol stamp applied as described 
in Section 5 of this Part. 



3.2.3 



DRAWINGS 



As appropriate, drawings shall be prepared to A07 
describe the repair or alteration. Drawings shall 
include sufficient information to satisfactorily 
perform the repair or alteration. 



3.2.4 DESIGN REQUIREMENTS FOR 

REPAIRS AND ALTERATIONS 

a) Many repairs may not require drawings or A07 
design calculations when the original code 

of construction is known and drawings and/ 
or a Manufacturer's Data Report is avail- 
able. 

b) The "R" certificate holder performing A07 
repairs and alterations shall establish the 
construction standard or code and sufficient 
controls to ensure that all required design 
information, applicable drawings, design 
calculations, specifications, and instruc- 
tions are prepared, obtained, controlled, 
and interpreted to provide the basis for a 
repair or an alteration in accordance with 

the original code of construction. When 
a Manufacturer's Data Report is required 
by the original construction standard, a 
copy of the original data report shall be 
obtained, where available, for use in the A07 
design of the repair or alteration. When 
the original Manufacturer's Data Report 
cannot be obtained, agreements on the 
method of establishing design basis for the 
repair or alteration shall be obtained from 
the Inspector and the Jurisdiction, when A07 
required. 



6 i 



NATIONAL BOARD INSPECTION CDDE 



PART 3 



REPAIRS AND ALTERATIONS 



3.2.5 



CALCULATIONS 



3.3.2 



ROUTINE REPAIRS 



A07 For alterations, calculations shall be completed 
prior to the start of any physical work. All design 
calculations shall be completed by an organiza- 
tion experienced in the design portion of the 
standard used for construction of the item. All 
calculations shall be made available for review 
by the Inspector accepting the design. 



A09 3.2.6 REFERENCE TO OTHER CODES 

AND STANDARDS 
Other codes, standards, and practices pertain- 
ing to the repair and alteration of pressure 
retaining items can provide useful guidance. 
Use of these codes, standards and practices 
is subject to review and acceptance by the 
Inspector, and when required, by the Jurisdic- 
tion. The user is cautioned that the referenced 
codes, standards and practices may address 
methods categorized as repairs; however, some 
of these methods are considered alterations by 
the NBIC. 

In the event of a conflict with the requirements 

of the NBIC, the requirements of the NBIC take 

precedence. 

Some examples are as follows: 

(a) National Board Bulletin - National Board 
Classic Articles Series. 

(b) ASME PCC-1, Guidelines for Pressure 
Boundary Bolted Flange Joint Assembly . 

(c) ASME PCC-2, Repair of Pressure Equipment 
and Piping. 



A07 3.3 



3.3.1 



REPAIRS TO PRESSURE- 
RETAINING STEMS 



DEFECT REPAIRS 



Before a repair is made to a defect in a welded 
joint or base metal, care should be taken to 
investigate its cause and to determine its extent 
and likelihood of recurrence. 



a) Routine repairs are repairs for which the 
requirements for in-process involvement 
by the Inspector and stamping by the "R" 
certificate holder may be waived as de- 
termined appropriate by the Jurisdiction 
and the Inspector. All other applicable 
requirements of this Code shall be met. 
Prior to performing routine repairs, the 
"R" certificate holder should determine 
that routine repairs are acceptable to the 
Jurisdiction where the pressure-retaining 
item is installed. 

b) The Inspector, with the knowledge and un- 
derstanding of jurisdictional requirements, 
shall be responsible for meeting jurisdic- 
tional requirements and the requirements 
of this Code. 

c) The "R" certificate holder's quality system 
program shall describe the process for 
identifying, controlling, and implement- 
ing routine repairs. Routine repairs shall 
be documented on Form R-1 with this 
statement in the Remarks section: "Routine 
Repair." 

d) Repairs falling within one or more of the 
following categories may be considered 
routine: 

1) Welded repairs or replacements of 
valves, fittings, tubes, or pipes NPS 5 
(DN 125) in diameter and smaller, or 
sections thereof, where neither post- 
weld heat treatment nor NDE other 
than visual is required by the original 
code of construction. This includes their 
attachments such as clips, lugs, skirts, 
etc., but does not include nozzles to 
pressure-retaining items. 

2) The addition or repair of nonload bear- 
ing attachments to pressure-retaining 
items where postweld heat treatment 
is not required. 

3) Weld buildup of wasted areas not 
exceeding an area of 100 sq. inches 



62 



NATIONAL BOARD INSPECTION CDDE • PART 3 — REPAIRS AND ALTERATIONS 



(64,520 sq. mm) or a thickness of 25% 
of nominal wall thickness or V2 inch (1 3 
mm), whichever is less. 

4) Corrosion resistance weld overlay 
not exceeding 100 sq. in. (64,520 sq. 
mm). 



1) Replacement of furnace floor tubes 
and/or sidewall tubes in a boiler 

2) Replacement of a shell or head in ac- 
cordance with the original design 

3) Rewelding a circumferential or longi- 
tudinal seam in a shell or head 



3.3.3 



EXAMPLES OF REPAIRS 



a) Weld repairs or replacement of pressure 
parts or attachments that have failed in a 
weld or in the base material; 

b) The addition of welded attachments to pres- 
sure parts, such as: 

1 ) Studs for insulation or refractory lining; 

2) Hex steel or expanded metal for refrac- 
tory lining; 

3) Ladder clips; 

4) Brackets having loadings that do not af- 
fect the design of the pressure-retaining 
item to which they are attached; and 

5) Tray support rings. 

c) Corrosion resistant strip lining, or weld 
overlay; 

d) Weld buildup of wasted areas; 

e) Replacement of heat exchanger tubesheets 
in accordance with the original design; 

f) Replacement of boiler and heat exchanger 
tubes where welding is involved; 

g) In a boiler, a change in the arrangement 
of tubes in furnace walls, economizer, or 
super heater sections; 

h) Replacement of pressure-retaining parts 
identical to those existing on the pressure- 
retaining item and described on the original 
Manufacturer's Data Report. For example: 



4) Replacement of nozzles of a size where 
reinforcement is not a consideration 

i) Installation of new nozzles or openings of 
such a size and connection type that re- 
inforcement and strength calculations are 
not a consideration required by the original 
code of construction; 

j) The addition of a nozzle where reinforce- 
ment is a consideration may be considered 
to be a repair, provided the nozzle is identi- 
cal to one in the original design, located in 
a similar part of the vessel, and not closer 
than three times its diameter from another 
nozzle. The addition of such a nozzle shall 
be restricted by any service requirements; 

k) The installation of a flush patch to a pres- 
sure-retaining item; 

I) The replacement of a shell course in a cy- 
lindrical pressure vessel; 

m) Welding of gage holes; 

n) Welding of wasted or distorted flange 
faces; 

o) Replacement of slip-on flanges with weld 
neck flanges or vice-versa; 

p) Seal welding of buttstraps and rivets; 

q) Subject to the administrative procedures of 
the jurisdiction and approval of the Inspec- 
tor, the replacement of a riveted section or 
part by welding; 

r) The repair or replacement of a pressure part 
with a code-accepted material that has a 
nominal composition and strength that is 



63 



NATIONAL BDARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



equivalent to the original material, and is 
suitable for the intended service; and 

s) Replacement of a pressure-retaining part 
with a material of different nominal com- 
position, equal to or greater in allowable 
stress from that used in the original design, 
provided the replacement material satisfies 
the material and design requirements of the 
original code of construction under which 
A08 the vessel was built. The minimum required 
thickness shall be at least equal to the thick- 
ness stated on the original Manufacturer's 
Data Report. 

The replacement of a Pressure Relieving 
Device (PRD) attached by welding, pro- 
vided the replacement device's relieving 
capacity is equal to or greater than the 
PRD-capacity required by the original code 
of construction. 



3.3.4 REPAIR METHODS 



3.3.4.1 SCOPE 

A09 Except as provided in 3.3.4.8 a repair of a 
defect in a welded joint or base material 



A09t) 



shall not be made until the defect has been 
removed. A suitable Nondestructive Examina- 
tion (NDE) method such as Magnetic Particle 
(MT) or Liquid Penetrant (PT) may be necessary 
to ensure complete removal of the defect. If 
the defect penetrates the full thickness of the 
material, the repair shall be made with a full 
penetration weld such as a double buttweld 
or single buttweld with or without backing. 
Where circumstances indicate that the defect 
is likely to recur, consideration should be given 
to removing the defective area and installing a 
flush patch or taking other corrective measures 
acceptable to the Inspector and when required 
by the Jurisdiction. 



3.3.4.2 



DEFECT REPAIRS 



a) Cracks 

Except as provided in 3.3.4.8, a repair of A09 
a crack in a welded joint or base material 
shall not be made until the defect has been 
removed. A suitable nondestructive exami- 
nation method such as a MT or PT may be 
necessary to ensure complete removal of 
the defect. If the defect penetrates the full 
thickness of the material, the repair shall 
be made with a full penetration weld such 



FIGURE 3.3.4.2-a 
Unstayed Boiler Furnaces 




Cracks at the knuckle or at the turn of the furnace opening require immediate 
replacement of the affected area. If repairs are attempted, specific approval of 
the jurisdiction is required. 



64 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



as a double butt weld or single butt weld 
with or without backing, as allowed by the 
original code of construction. 

b) Unstayed Boiler Furnace Cracks 

Cracks at the knuckle or at the turn of the 
flange of the furnace opening require im- 
mediate replacement of the affected area or 
specific approval of repairs by the Jurisdic- 
tion. (See Figure 3.3.4.2-a). 

c) Rivet or Staybolt Hole Cracks 

Cracks radiating from rivet or staybolt holes 
may be repaired if the plate is not seriously 
damaged. If the plate is seriously damaged, 
it shall be replaced. For suggested methods 
of repair, (see Figure 3.3.4.2-b). 



d) Minor Defects 

Minor cracks, isolated pits, and small plate 
imperfections should be examined to deter- 
mine the extent of the defect and whether 
repair by welding is required. Except as A09 
provided in 3.3.4.8 prior to repair by weld- 
ing, the defects shall be removed to sound 
metal. Liquid penetrant or magnetic particle 
examination may be used before or after 
welding. 

e) Defective Bolting 

Defective bolting material shall not be re- 
paired but shall be replaced with suitable 
material that meets the specifications of the 
original code of construction. 



FIGURE 3.3.4.2-b 

Rivet and Staybolt Hole Cracks 

Cracks radiating from rivet or staybolt holes should be repaired if the plate is not seriously damaged. If the plate is 
seriously damaged, it shall be replaced. A suggested repair method is described below: 

a. Prior to welding, the rivets or staybolts from which the cracks extend and the adjacent rivets (or staybolts if ap- 
propriate) should be removed. 

b. In riveted joints, tack bolts should be placed in alternate holes to hold the plate laps firmly. 

c. The cracks should then be prepared for welding by chipping, grinding, or gouging. 

d. In riveted joints, cracks which extend past the inner edge of the plate lap should be welded from both sides. 

e. Rivet holes should be reamed before new rivets are driven. 

f. Threaded staybolt holes should be retapped and new staybolts properly driven and headed. 




Circumferential Cracks at Girth Seams 





Fire Cracks at Girth Seams 




o 

o 



Fire Cracks at Door Openings 



Cracks in Stayed Plates 



65 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



f) Bulges 

1) A bulge on a watertube shall be investi- 
gated to determine the cause and extent 
of damage to the tube prior to repair. If 
the bulge has resulted in metallurgical 
changes to the original tube material, 
as determined by field metallography, 
installation of a new length of tubing or 
tube patch (see 3.3.4.6[b]) is required. 
If the bulge has cracks as determined 
by NDE, installation of a new length of 
tubing or a tube patch is required. If the 
bulge does not exhibit cracks and has 
not resulted in metallurgical changes to 
the original tube material, a mechani- 
cal repair may be considered subject 
to the concurrence of the Inspector or 
Jurisdiction. 

2) A bulge on a plate shall be investigated 
to determine the cause and extent of 
damage to the plate prior to repair. If 
the bulge has resulted in metallurgical 
changes to the original plate material, 
as determined by field metallogra- 
phy, installation of a flush patch (see 
3.3.4. 6[a]) is required. If the plate has 
cracks as determined by NDE, installa- 
tion of a flush patch is required. If the 
bulge does not exhibit cracks and has 
not resulted in metallurgical changes to 
the original plate material, a mechani- 
cal repair may be considered, subject 
to the concurrence of the Inspector or 
Jurisdiction. 

g) Blisters 

A blister may be caused by a defect in the 
metal such as lamination where one side 
exposed to the fire overheats but the other 
side retains its strength due to the cooling 
effect of the water. After the bl istered mate- 
rial has been removed, the remaining wall 
thickness shall be determined by ultrasonic 
thickness testing. A surface examination 
using liquid penetrant testing or magnetic 
particle testing shall be made to assure the 
remaining material contains no defects. If 
the remaining wall thickness is adequate, 



in the judgment of the Inspector, the area 
may be repaired by welding as covered 
in 3.3.4.3, Wasted Areas. If the remaining 
wall thickness is not adequate, a plate will 
require a flush patch (See 3.3.4.6[a]) and 
a tube will require a new length of tube or 
tube patch (see 3.3.4.6[b]). 



3.3.4.3 



WASTED AREAS 



a) Shells, Drums, Headers 

Wasted areas in stayed and unstayed shells, 
drums, and headers may be built up by 
welding, provided that in the judgment of 
the Inspector the strength of the structure 
has not been impaired. Where extensive 
weld buildup is employed, the Inspector 
may require an appropriate method of NDE 
for the completed surface of the repair. For 
suggested methods of building up wasted 
areas by welding. (See Figure 3.3.4.3-a). 

b) Access Opening 

Wasted areas around access openings may 
be built up by welding or they may be re- 
paired as described in Figure 3.3.4.3-b. 

c) Flanges 

Wasted flange faces may be cleaned thor- 
oughly and built up with weld metal. They 
should be machined in place, if possible, to 
a thickness not less than that of the original 
flange or that required by calculations in ac- 
cordance with the provisions of the original 
code of construction. Wasted flanges may 
also be re-machined in place without build- 
ing up with weld metal, provided that metal 
removed in the process does not reduce the 
thickness of the flange to a measurement 
below that calculated above. Flanges that 
leak because of warpage or distortion and 
which cannot be re-machined shall be re- 
placed with new flanges that have at least 
the dimensions conforming to the original 
code of construction. 

d) Tubes 

Wasted areas on tubes may be repaired by 
welding, provided that in the judgment of 
the Inspector the strength of the tube has 



66 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



not been impaired. Where deemed neces- 
sary, competent technical advice should 
be obtained from the manufacturer or from 
another qualified source. This may be nec- 
essary when considering such items as size 
limitations of repaired areas, minimum tube 
thickness to be repaired, tube environment, 
location of the tube in the boiler, and other 
similar conditions. 

A07 e ) External Weld Metal Buildup 

A08 1 ) Pressure-retaining items that have local- 
ized internal thinning due to erosion 

A08 and/or corrosion and where the internal 

surface is not readily accessible may be 
weld repaired by depositing weld metal 
on the external surface of the item as 

A08 shown in Figure 3. 3.4. 3-c. This method 

of repair is subject to approval by the 
Inspector and the Jurisdiction, where 
required. 

A07 2) All of the following conditions shall 
apply for this repair method to be per- 
mitted: 

A07 a. The component to be repaired shall 

A08 be a ferrous material. 

A07 b. The maximum design temperature 

of the repaired component shall 
not exceed 650°F (340°C), and the 
minimum design temperature shall 
not be less than -20°F (-29°C). 

A07 c. The pressure-retaining item shall be 

volumetrically examined for cracks 
in the area to be weld repaired. 
If cracks are detected, this repair 
method shall NOT be used. 

A07 d. The WPS followed shall be quali- 

fied for weld metal buildup in 
accordance with ASME Section 
IX. The nominal chemical analysis 
of the deposited weld metal shall 
be equivalent to the base material 
that is to be repaired. In addition, 
the nominal tensile strength of the 
deposited weld metal shall be equal 



to or exceed the specified minimum 
tensile strength and shall be based 
on the requirements of the welding 
consumable. If butt joints in the 
component being overlaid required 
postweld heat treatment (PWHT) by 
the code of construction, the WPS 
followed for the weld buildup shall 
be given PWHT. 

e. The pressure-retaining item shall A07 
be taken out of service prior to 
performing the weld metal buildup. 
The owner of the pressure-retaining 
item shall evaluate the flammabil- 

ity, volatility, or potential reaction of 
the contents that were in the vessel 
to ensure safe working conditions 
during weld repair. When required 
by the results of this evaluation, the 
pressure-retaining item shall be 
drained of its contents to the extent 
necessary to make the repair. 

f. This method may be used more A07 
than once in the same areas to 
repair locally thinned areas; how- 
ever , the cumulative weld buildup 

for all repairs shall not exceed the 
thickness (t) of the component at 
any point. 

g. Repairs using this method shall 
not cover more than 25% of the 
circumference of the component. 

3) External weld buildup shall be applied A07 
in accordance with the following re- 
quirements: 

a. The area to be repaired shall be 
ultrasonically scanned for wall 
thickness, and the location and 
size of the thinned region shall be 
mapped. 

b. The area requiring repairs and the A07 
boundaries of the weld buildup 
shall be marked on the external 
surface of the component. 



67 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



FIGURE 3.3.4.3-a 

Weld Buildup of Wasted Area 

Rivet and Staybolts 

a. Prior to welding, the rivets or staybolts in the wasted area should be removed. 

b. Threaded staybolt holes should be retapped after welding. 

c. Rivet holes should be reamed after welding. 

d. Welding should not cover rivet or staybolt heads. 




Tubesheet 

a. Prior to welding, the tubes in the wasted area should be removed. 

b. After welding, the tube holes may be reamed before new tubes are installed. 




Tubes 



Wasted areas in stayed and unstayed surfaces may be repaired by weld buildup, provided that in the judgment of 
the inspector the strength of the structure will not be impaired. Where extensive weld buildup is employed, the 
inspector may require an appropriate method of NDE for the complete surface of the repair. 



68 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



FIGURE 3.3.4.3-b 

Repairs for Access Openings 

A badly wasted manhole flange may be removed and replaced with a ring-type frame as shown below. The 
requirements for flush patches shall be met. A full penetration weld is required. May be either double or welded 
from one side with or without a backing ring. 




<o □>? 



^— Backing Ring 

3 



Pressure Side 



A badly wasted area around a handhole opening may be repaired by adding a ring, as shown below, on the 
inside of the object. 

Wasted area removed 7 _ . . 

..,.y£.f^Onoinal e< *0 e o( opening 
«■■'■■•*■■■ Ring 




Minimum lap 
Vi In. (12.7 mm) 



Pressure Side 



A07 



FIGURE 3.3.4.3-c 

External Overlay Terms and Definitions 




L = length of area to be repaired along the 
axis of the component 

C = length of area to be repaired along out- 
side circumference of the component 

W =the completed thickness of the overlay 

4 = the angle between the component and 
the overlay (maximum 45°) 

B = 3/4 V(R t) minimum 

R = nominal outside radius of the compo- 
nent 

the nominal outside diameter of the 
component 

nominal wall thickness of the 
component 

p = remaining wall thickness of the 
component shall be 1/16 or greater 

R = minimum radius, not less than the over- 

lav thickness 



D 



t = 



A09 



69 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



A07 



A07 



c. The general design of the external 
weld buildup shall be in accor- 
dance with Figure 3.3.4.3-c. The 
finished weld buildup shall be 
circular, oval, or rectangular in 
shape. 

d. The weld buildup shall extend, at 
full thickness, a minimum distance 
B in each direction beyond the 
boundaries of the thinned base 
metal area. 

1. B =3/4VRt 

nom 

2. R = outer radius of the com- 
ponent, or D/2 

3. t n m = nominal wall thickness 
of the component 

The thickness shall be sufficient 
to maintain the predicted life of 
the repair. Any corrosion allow- 
ance that is determined to be 
necessary shall be added to the 
value of B. 



e. All edges of the weld buildup shall be A07 
tapered to the existing contour of the com- 
ponent, at a maximum angle (a) of 45°. 

f. The thickness of the weld buildup shall A07 
be uniform except along tapered edges as 
welded surfaces are acceptable, provided 
they are free of coarse ridges and valleys 
and are suitable for any required nonde- 
structive examinations. 

g. All corners of the weld buildup shall have A07 
a minimum radius (r), not less than the 
overlay thickness. 

h. Any corrosion allowance that is determined 
to be necessary shall be added to the thick- 
ness of the weld buildup. 

i. The thickness (W) of the weld deposit plus A07 
the remaining wall thickness in the affected 
area (u) of the component at its thinnest 
point shall not exceed the nominal wall 
thickness (t) of the component. This shall 
be verified by ultrasonic methods. 



FIGURE 3.3.4.4-a 

Typical Examples of Seal Welding Tubes 

Tubes may be seal welded provided the ends of the tubes have sufficient wall thickness to prevent burn-through. 
Seal welding shall be applied in strict accordance with the original code of construction for the requirements of 
the tube projection, welding, and tube expanding. Seal welding shall not be considered a strength weld. 

In watertube boilers, tubes may be seal welded on the inside or outside of the tubesheet. 



f-\ 



tD r 



s\ 



-m 



-\ 



I 




I 



7D 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



A07 j- Final dimension and contour of the weld 
buildup may be achieved by grinding or 
machining. This work may be done before 
or after any PWHT. 

A07 k. The weld buildup shall be examined by 
liquid penetrant inspection or wet fluores- 
cent magnetic particle inspection. If the 
butt welds in the component being built 
up were required to be volumetrically ex- 
amined during the original construction, 



the built-up area shall be similarly volu- 
metrically examined. 

For each repair, the maximum dimension A07 
(L, length along axis) compensated by a 
circular or oval weld buildup shall not ex- 
ceed the lesser of 1/4 the nominal outside 
diameter or the component of 8 in. (200 
mm). The length of a rectangular patch is 
not limited. 



FIGURE 3.3.4.4-b 

Seal Welding of Riveted Joints 

Seal welding of riveted joints requires the approval of the Jurisdiction. Seal welding shall not be considered a 
strength weld. Prior to welding, the area should be examined by an appropriate method of NDE to ensure that 
there are no cracks radiating from the rivet holes. If necessary, the rivets should be removed to ensure complete 
examination of the area. Seal welding should not be performed if cracks are present in riveted areas. 



Throat approx. 1/8 in. (3.2 mm) 



Typical Rivet Joint Showing Seal Weld 




FIGURE 3.3.4.5 






Re-Ending or Piecing of Pipes or Tubes 






mMtfp 

\ 


■ v 

\ 








re-ending 


piecing 



A07 



71 



NATIONAL BOARD INSPECTION CDDE • PART 3 



REPAIRS AND ALTERATIONS 



A07 m. The distance between the weld toes of the 
multiple weld buildup regions on a com- 
ponent outer diameter surface area shall 
not be less than 3/4 V(Rt). 



proval of the Jurisdiction. If seal welding is 
approved, suggested methods and precau- 
tions are shown in Figure 3.3.4.4-b. 



3.3.4.4 SEAL WELDING 

a) Seal Welding of Tubes 

Tubes may be seal welded, provided the 
ends of the tubes have sufficient wall 
thickness to prevent burn-through and the 
requirements of the original code of con- 
struction are satisfied as shown in Figure 
3.3.4.4-a. 

b) Seal Welding of Riveted Joints 

Edges of buttstraps, plate laps, and nozzles, 
or of connections attached by riveting, 
may be restored to original dimensions 
by welding. Seal welding of riveted joints, 
buttstraps, or rivets shall require the ap- 



3.3.4.5 RE-ENDING OR PIECING PIPES 
ORTUBES 

Re-ending or piecing pipes or tubes is permit- 
ted, provided the thickness of the remaining 
pipe or tube is not less than the minimum thick- A07 
ness required by the original code of construc- 
tion. (See Figure 3.3.4.5). 



3.3.4.6 PATCHES 

a) Flush Patches 

1) The weld around a flush patch shall 
be a full penetration weld and the 
accessible surfaces shall be ground 



FIGURE 3.3.4.6-a 

Flush Patch Configurations in Unstayed Areas 



f"f"^.\ 



< z.' 





A07 



Flush Patches in Stayed Areas 



A07 




72 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



FIGURE 3.3.4.6-b 

Tube Window Patching Method 

It may be necessary to weld a flush patch on a tube since, in some situations, accessibility around the complete 
circumference of the tube is restricted. Listed below are the suggested methods for making window patches: 

a) The patch should be made from tube material of the same type, diameter, and thickness as the one being 
repaired. 

b) Fit-up of the patch is important to weld integrity. The root opening should be uniform around the patch. 

c) The gas tungsten-arc welding process should be used for the inital pass on the inside Of the tube and for the 
inital pass joining the patch to the tube. 

d) The balance of the weld may be completed by any appropriate welding process. 



Front and Side 
View of Tube 



Side View Showing 
Patch Fit and 
Welding 




Weld 
inside 




Bevel Outside 

25° - 35° 




Detail of 
Patch 




73 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



flush where required by the applicable 
original code of construction. Examples 
of flush welded patches are shown in 
Figure 3.3.4.6-a. The welds shall be 
subjected to the nondestructive ex- 
amination method used in the original 
code of construction or an alternative 
acceptable to the Inspector. 

2) Before installing a flush patch, the 
defective material should be removed 
until sound material is reached. The 
patch should be rolled to the proper 
shape or curvature. The edges should 
align without overlap. In stayed areas, 
the weld seams should come between 
staybolt rows or riveted seams. Patches 
shall be made from a material whose 
composition and thickness meet the 
intended service. Patches may be any 
shape or size. If the patch is rectangular, 
an adequate radius should be provided 
at the corners. Square corners should 
A07 be avoided. The completed welds shall 

meet the requirements of the original 
code of construction. 

b) Tube Patches 

In some situations it is necessary to weld a 
flush patch on a tube, such as when replac- 
ing tube sections and accessibility around 
the complete circumference of the tube is 
restricted, or when it is necessary to repair 
a small bulge. This is referred to as a win- 
dow patch. Suggested methods for window 
patches are shown in Figure 3.3.4.6-b. 



3.3.4.8 REPAIR OF PRESSURE- A09 

RETAINING ITEMS WITHOUT 
COMPLETE REMOVAL OF 
DEFECTS 

a) There may be cases where removal of a 
defect in a pressure-retaining item is not 
practical at the time the defect is found. In 
such cases, with approval of the Inspector 
and, when required, the Jurisdiction, an 
engineering evaluation shall be performed 
to determine the scope of the repair and 
impact to safety prior to returning the 
pressure-retaining item to service for a 
specified period of time. The engineering 
evaluation shall be performed by an orga- 
nization with demonstrated competency 
in defect (and flaw) characterization of . 
pressure-retaining items. The method of 
defect evaluation and time interval for 
returning the pressure-retaining item back 
to service shall be as agreed upon by the 
Inspector, and when required, the Jurisdic- 
tion. The specified period of time the defect 
can remain in service after weld repair 
shall be based on no measureable defect 
growth during subsequent inspections, or 
a period of time as specified by the Juris- 
diction, if applicable. This repair method 
is not permitted for vessels used in lethal 
service, vessels designed for high-cycle 
operation or fatigue service, compressed 
air storage, and in cases where high stress 
concentration cannot be reduced by weld 
repair. This repair method is not permitted 
for DOT vessels. 



3.3.4.7 



STAYS 



Threaded stays may be replaced by welded-in 
stays provided that, in the judgement of the In- 
spector, the material adjacent to the staybolt has 
not been materially weakened by deterioration 
or wasting away. Requirements of the original 
code of construction governing welded-in stays 
shall be met. 



b) One or more fitness-for-service engineering 
evaluation methods as described in NBIC, 
Part 2, 4.4, shall be used to determine A09 
whether the defect may remain, either in part 
or in whole, in the pressure-retaining item. 
If it is determined that the defect can remain 
in the item, a risk-based inspection program 
shall be developed to assure inspection of 
the defect and monitoring of defect growth 
over time. This program shall be a controlled 
and documented inspection program that 
specifies inspection intervals as agreed upon 
with the Inspector and, when required, the 



74 



NATIDNAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



Jurisdiction, and shall be maintained until 
the defect can be completely removed and 
the item repaired. 

c) The following requirements shall apply to 
the weld repair of pressure-retaining items 
without complete removal of defects; 

1) Engineering evaluation of the defect 
in the pressure-retaining item shall 
be conducted using one or more 
fitness-for-service condition assessment 
method(s) as described in NBIC, Part 
2, 4.4. Engineering evaluation of the 
condition assessment results shall be 
performed by an organization that has 
demonstrated industry experience in 
evaluating pressure-retaining items as 
referenced in NBIC, Part 2, S5.3. 

2) If engineering evaluation indicates a de- 
fect can remain in the pressure-retaining 
item, a risk-based inspection program 
shall be developed and implemented 
based on review and acceptance by 
the Inspector and, when required, the 
Jurisdiction. The risk-based inspection 
program shall be in accordance with 
the requirements in NBIC, Part 2, 4.4. 

3) The fitness-for-service condition as- 
sessment and risk-based inspection 
programs shall remain in effect for 
the pressure-retaining item until such 
time that the defect can be completely 
removed and the item repaired. The 
fitness-for-service condition assess- 
ment method, results of assessment, 
and method of weld repair shall be 
documented on a Report of Fitness for 
Service Assessment (FFSA) Form as de- 
scribed in NBIC, Part 2, 4.4.1 and shall 
be filed with the Jurisdiction, when 
required. 

4) When weld repairs are performed with- 
out complete removal of the defect(s), 
this shall be noted on the Form R-1 in 
the description of the work. The R-Stamp 
holder performing the weld repairs shall 
provide detailed information on the 



Form R-1, describing the method and 
extent of repair and include the specific 
location of the repair on the item. 

5) The interval to either re-inspect or re- 
move the item from service for repair 
shall be determined based on a risk- 
based inspection program developed 
and implemented as required by Para- A07 
graph 3.3.4.8. The inspection interval 
shall not exceed the remaining life of 

the item, and shall be documented on 
the FFSA Form and in the remarks sec- 
tion of the Form R-1 . The FFSA Form 
shall be affixed to the Form R-1 when 
weld repairs are performed in 3.3.4.8. 

6) A copy of the completed Form R-1 with 
the completed FFSA Form attached may 
be registered with the National Board, 
and when required, filed with the Juris- 
diction where the item was installed. 



3.3.5 



3.3.5.1 



REPAIR OF ASME SECTION VIII, 
DIVISION 2 OR 3, PRESSURE 
VESSELS 



SCOPE 



The following requirements shall apply for the 
repair of pressure vessels constructed to the 
requirements of Section VIII, Division 2 or 3, 
of the ASME Code. 



3.3.5.2 



REPAIR PLAN 



The user shall prepare or cause to have pre- 
pared a detailed plan covering the scope of 
the repair. 

a) Engineer Review and Certification 



A09 



The repair plan shall be reviewed and certi- 
fied by an Engineer meeting the criteria of A09 
ASME Section VIII, Division 2 or 3, as appli- 
cable, for an Engineer signing and certifying 
a Manufacturer's Design Report. The review 
and certification shall be such as to ensure 



75 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



A09 



b) 



the work involved in the repair is compat- 
ible with the User's Design Specification 
and the Manufacturer's Design Report. 

NOTE: The Engineer qualification crite- 
ria of the jurisdiction where the pressure 
vessel is installed should be verified be- 
fore selecting the certifying Engineer. 

Authorized Inspection Agency Acceptance 
Following review and certification, the 
repair plan shall be submitted for accep- 
tance to the Authorized Inspection Agen- 
cy/Owner-User Inspection Organization 
whose Inspector will make the acceptance 
inspection and sign the Form R-1 . 



c) Current inspection records verify that the 
pressure-retaining item is satisfactory for 
the proposed service conditions. 

d) The pressure-retaining item has been pres- 
sure tested, as required, for the new service 
conditions. Any insulation, coatings, or 
coverings that may inhibit or compromise a 
meaningful pressure test shall be removed, 
to the extent identified by the Inspector. 

e) In lieu of pressure testing, alternative meth- 
ods can be used to ensure the structural 
integrity of the re-rated pressure-retaining 
item. The alternative methods shall be 
documented and subject to review and 
approval by the Jurisdiction. 



3.4 



3.4.1 



ALTERATIONS 



RE-RATING 10 



Re-rating of a pressure-retaining item by in- 
creasing the maximum allowable working 
pressure (internal or external) or temperature 
or decreasing the minimum design metal tem- 
perature below which notch toughness testing 
is required by the original code of construction, 
shall be done only after the following require- 
ments have been met to the satisfaction of the 
Jurisdiction at the location of the installation: 

a) Revised calculations verifying the new 
service conditions shall be prepared in ac- 
cordance with the "R" certificate holder's 
Quality Control System. Establishing a 
higher joint efficiency to re-rate a pressure- 
retaining item is not permitted. 

b) All re-ratings shall be established in ac- 
cordance with the requirements of the 
construction standard to which the pres- 
sure-retaining item was built. 



10 Re-rating: Except as provided for Yankee Dryers in Sup- 
plement 5, this code does not provide rules for de-rating boilers 
or pressure vessels; however, when the MAWP and/or allow- 
able temperature of a boiler or pressure vessel is reduced, the 
Jurisdiction where the object is installed should be contacted to 
determine if specific procedures should be followed. 



3.4.2 ALTERATIONS BASED ON AL- 

LOWABLE STRESS VALUES 

For re-rating or re-calculating a new minimum 
wall thickness for a pressure-retaining item 
using a later edition/addenda of the original 
code of construction or selected construction 
standard or code that permits use of higher al- 
lowable material stress values than were used 
in the original construction, the following re- 
quirements shall apply: 

a) The "R" certificate holder shall verify, by 
calculations and other means, that the re- 
rated item can be satisfactorily operated at 
the new service condition (e.g., stiffness, 
buckling, external mechanical loadings). 

b) The pressure-retaining item shall not be 
used in lethal service. 

c) The pressure-retaining item shall not be 
used in high-cycle operation or fatigue ser- 
vice (i.e., loadings other than primary mem- 
brane stress are controlling design consid- 
erations) unless the pressure-retaining item 
was originally designed for fatigue service 
and a fatigue analysis is performed. 



76 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



d) The pressure-retaining item shall have been 
constructed to the 1968 edition or later 
edition/addenda of the original code of 
construction. 

e) The pressure-retaining item shall be shown 
to comply with all relevant requirements 
of the edition/addenda of the code of 
construction, which permits the higher al- 
lowable stress values (e.g., reinforcement, 
toughness, examination, pressure testing). 

f) The pressure-retaining item shall have a 
satisfactory operating history and current 
inspection of the pressure-retaining item 
shall verify the item exhibits no unrepaired 
damage (e.g., cracks, corrosion, erosion). 
Areas of corrosion or erosion may be left 
in place provided the remaining wall thick- 
ness is greater than the minimum thickness 
for the new design conditions. 

g) The re-rating shall be acceptable to the 
Inspector and, where required, the Jurisdic- 
tion. 

h) All other requirements of Part 3, as appli- 
cable, and jurisdictional requirements shall 
be met. 



e) In a boiler, an increase in the heating sur- A09 
face or steaming capacity as described on 

the original Manufacture's Data Report. 

f) The addition of a pressurized jacket to a 
pressure vessel; 

g) Except as permitted in NBIC, Part 3, 3.3.3 
s), replacement of a pressure-retaining part 
in a pressure-retaining item with a material 
of different allowable stress or nominal 
composition from that used in the original 
design; and 

h) The addition of a bracket or an increase in A09 
loading on an existing bracket that affects 
the design of the pressure-retaining item to 
which it is attached. 

i) The replacement of a Pressure Relieving 
Device (PRD) as a result of work completed 
on a Pressure-retaining Item (PRI) that 
changes the resultant capacity to exceed 
the Minimum Required Relieving Capacity 
(MRRC) required by the original code of 
construction as described on the original 
Manufacturer's Data Report. 



i) Use of this paragraph shall be documented 
in the "Remarks" section of Form R-2. 



3.4.4 



ALTERATION OF ASME CODE 
SECTION VIII, DIVISION 2 OR 
3, PRESSURE VESSELS 



3.4.3 



EXAMPLES OF ALTERATIONS 



a) An increase in the maximum allowable 
working pressure (internal or external) or 
temperature of a pressure-retaining item 
regardless of whether or not a physical 
change was made to the pressure-retaining 
item; 

b) A decrease in the minimum temperature; 

c) The addition of new nozzles or openings 
in a boiler or pressure vessel except those 
classified as repairs; 

d) A change in the dimensions or contour of 
a pressure-retaining item; 



3.4.4.1 



ALTERATION PLAN 



a) Engineer Review and Certification 

The alteration plan shall be reviewed and A09 
certified by an Engineer meeting the cri- 
teria of ASME Section VIII, Division 2 or 
3, as applicable, for an Engineer signing 
and certifying a Manufacturer's Design 
Report. The review and certification shall 
be such as to ensure the work involved in 
the alteration is compatible with the user's 
design specification and the Manufacturer's 
Design Report. 



76.1 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



A09 NOTE: The Engineer qualification 

criteria of the jurisdiction where the 
pressure vessel is installed should be 
verified before selecting the certifying 
Engineer. 

b) User's Design Specification 

If the alteration is such that the work is not 
compatible with or changes one or more 
requirement(s) of the original user's design 
specification, the user's design specification 
shall be revised by the user with the new 
A"" parameters or changes. The revisions shall 
be certified by an Engineer meeting the cri- 
teria of ASME Section VIII, Division 2 or 3, 
as applicable, for an Engineer signing and 
certifying a Manufacturer's Design Report. 

A09 NOTE: The Engineer qualification 

criteria of the jurisdiction where the 
pressure vessel is installed should be 
verified before selecting the certifying 
Engineer. 

c) Manufacturer's Design Report 

The "R" Certificate holder shall prepare or 
cause to have prepared a supplement to the 
manufacturer's design report to reconcile 
the new parameters or changes with the 
user's design specification. 

The supplement to the Manufacturer's De- 
A09 sign Report shall be certified by an Engineer 
meeting the criteria of ASME Section VIII, 
Division 2 or 3, as applicable, for an Engi- 
neer signing and certifying a Manufacturer's 
Design Report. 

A09 NOTE: The Engineer qualification 

criteria of the jurisdiction where the 
pressure vessel is installed should be 
verified before selecting the certifying 
Engineer. 

d) Authorized Inspection Agency Acceptance 
Following review and certification, the 
alteration plan shall be submitted for accep- 
tance to the Authorized Inspection Agency/ 
Owner-User Inspection Organization 
whose inspector will make the acceptance 
inspection and sign the Form R-2. 



VS. 2 



4ATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



specifies requirements for a higher test 
temperature and it is acceptable to the 
Inspector. 

5) Hold-time for the pressure test shall be a 
minimum of 10 minutes prior to exami- 
nation by the Inspector. The test pressure 
shall be reduced to the MAWP for close 
examination by the Inspector. 

a. Hold-time for close examination 
shall be as necessary for the Inspec- 
tor to conduct the examination. 

b) Pneumatic Test 

A pneumatic test may be conducted when 
contamination of the pressure-retaining item 
by liquids is possible or when liquid pres- 
sure testing is not practicable. Concurrence 
of the owner shall be obtained in addition 
to the Inspector and Jurisdiction where 
required. Pneumatic test requirements and 
precautions shall be in accordance with the 
original code of construction. 

c) Nondestructive Examination 

NDE may be conducted when contami- 
nation of the pressure-retaining item by 
liquids is possible or when pressure test- 
ing is not practicable. Concurrence of the 
owner shall be obtained in addition to the 
Inspector and Jurisdiction where required. 
A08 Exclusive use of Visual Examination (VT) 
shall not be permitted. In all cases NDE 
methods or combination of methods used 
shall be suitable for providing meaningful 
results to verify the integrity of the altera- 
tion. 



4.5 PRESSURE RELIEF VALVE 

PERFORMANCE TESTING AND 
TESTING EQUIPMENT 

Each pressure relief valve to which the "VR" 
repair symbol stamp is to be applied shall be 
subjected to the following tests by the repair 
certificate holder. 



4.5.1 TEST MEDIUM AND TESTING 

EQUIPMENT 

Valves marked for steam service, or having 
special internal parts for steam service, shall 
be tested on steam. Valves marked for air, gas, 
or vapor service shall be tested with air or gas. 
Valves marked for liquid service shall be tested 
with water or other suitable liquid. ASME Code, 
Section IV hot-water valves, shall be tested on 
water, steam, or air. 

a) Each valve shall be tested to demonstrate 
the following: 

1) Set pressure (as defined by the valve 
manufacturer and as listed in NB-18, 
Pressure Relief Device Certifications); 

2) Response to blowdown, when required 
by the original code of construction; 

3) Seat tightness; and 

4) For valves designed to discharge to a 
closed system, the tightness of the sec- 
ondary pressure zone shall be tested 
as required by the original code of 
construction. 

b) The equipment used for the performance 
testing prescribed above shall meet the A09 
following requirements: 

1) The performance testing equipment 
shall include a pressure vessel of ad- 
equate volume and pressure source 
capacity to ensure compliance with 
4.5.1 a)1). 

2) Prior to use, all performance testing 
equipment shall be qualified by the 
certificate holder to ensure that the 
equipment and testing procedures will 
provide accurate results when used 
within the ranges established for that 
equipment. This qualification may be 
accomplished by benchmark testing, 
comparisons to equipment used for 



B 1 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



3) 



verification testing as specified in the 
quality system, or comparisons to field 
performance. This qualification shall be 
documented and provisions made to 
retain such documentation for a period 
of at least five years after the testing 
equipment is retired. Documentation 
of this qualification shall include but 
not be limited to: 

a. Schematic of the performance test 
equipment; 

b. Size and pressure ranges of valves 
to be tested and the test fluid to be 
used; 

c. Dimensions of test vessels; 

d. Accuracy of pressure measuring 
equipment; 

e. Size and design type of valves used 
to control flow; and 

f. Method of qualifying. 

Prior to the implementation of any 
addition or modification to the test- 
ing equipment that would alter the 
contents of the document required in 
4.5.1(b)(2), the certificate holder shall 
re-qualify the performance test equip- 
ment in accordance with 4.5.1(b)(2). 
If the equipment changed was used to 
satisfy the requirements of verification 
testing, the certificate holder shall no- 
tify the National Board and additional 
verification testing, in accordance with 
the quality system, may be required. 



ment, provided the valve manufacturer's cor- 
rections for differential in set pressure between 
steam and air are applied to the set pressure. 



4.5.3 



LIFT ASSIST TESTING 



a) A device may be used to apply an auxiliary 
lifting load on the spring of a repaired valve 
to establish the set pressure in lieu of the 
tests required in 4.5.1 a)1 ) when such testing 
at full pressure: 

1 ) may cause damage to the valve being 
tested; or 

2) is impractical when system design 
considerations preclude testing at full 
pressure. 

b) While actual valve blowdown and valve 
performance characteristics cannot be veri- 
fied, valve set pressure may be determined 
to an acceptable degree of accuracy using 
this testing technique provided, as a mini- 
mum, that: 

1) equipment utilized is calibrated as A07 
required in the quality system; 

2) the device and test procedures that have 
proved to give accurate results are used 
and followed; 

3) a static inlet pressure is applied with the 
test medium specified in 4.5.1; and 

4) adjustments are made in accordance 
with the valve manufacturer's recom- 
mendations to ensure proper lift and 
blowdown. 



4.5.2 OWNER-USER ASME CODE 

SECTION VIII STEAM TESTING 



4.5.4 



PRESSURE TEST OF PARTS 



When ASME Code Section VIII valves are re- 
paired by the owner for the owner's own use, 
valves for steam service may be tested on air for 
set pressure and, if possible, blowdown adjust- 



Parts used in repaired valves shall be pres- 
sure tested and documentation provided 
according to the following categories: 



82 




Part 3, Section 5 

Repairs and Alterations — 

Certificatidn/Ddcumentatidn and 

Stamping 



85 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 

PART 3, SECTION 5 
REPAIRS AND ALTERATIONS — 

CERTIFICATION/DOCUMENTATION AND STAMPING 



A07 5.1 



SCOPE 



A07 This section provides requirements for certifica- 
tion, stamping, and documentation of repairs 
and alterations to pressure-retaining items. 
Applicable forms are provided in this section 
for reference. Forms may be obtained from the 
National Board Web site. 



5.2 DOCUMENTATION 

a) Repairs that have been performed in accor- 
dance with the NBIC shall be documented 
on Form R-1, Report of Repair, as shown 
in this section. Form R-4, Report Supple- 
mentary Sheet, shall be used to record 
additional data when space is insufficient 
on Form R-1 . 

b) Alterations performed in accordance with 
the NBIC shall be documented on Form 
R-2, Report of Alteration, as shown in this 
section. Form R-4, Report Supplementary 
Sheet, shall be used to record additional 
data when space is insufficient on Form 
R-2. 



5.2.1 PREPARATION OF FORM R-1 

(REPAIRS) 

a) Preparation of Form R-1 shall be the re- 
sponsibility of the "R" certificate holder 
performing the repair. 

b) An Inspector shall indicate acceptance by 
signing the Form R-1 . 

c) The Form R-3 and the Manufacturer's Data 
Reports described in this section shall be a 
part of the completed Form R-1 and shall 
be attached thereto. 



5.2.2 PREPARATION OF FORM R-2 

(ALTERATIONS) 

a) Initial preparation of Form R-2 shall be the 
responsibility of the "R" certificate holder 
responsible for the design portion of the 
alteration. The design organization shall 
complete and sign the "Design Certifica- 
tion" section of the Form R-2. An Inspector 
shall indicate acceptance of the design by 
signing the "Certificate of Design Change 
Review" section of the Form R-2. 

b) The information describing an alteration to A09 
a pressure-retaining item shall be identified 

on Form R-2 with a complete description 
of the scope of work for physical or non- 
physical changes. When the scope of work 
represents a change that will increase the 
Minimum Required Relieving Capacity 
(MRRC) of a pressure-retaining item, such 
as a change in heating surface, Maximum 
Designed Steaming Capacity (MDSC), or 
Btu/hr (W) heating capacity, the new MRRC 
shall be documented on Form R-2 and 
indicated on the appropriate nameplate of 
Figure 5.7.5-b or Figure 5.7.5-c. 

c) Final preparation of Form R-2, including A09 
the gathering and attaching of supporting 
reports, shall be the responsibility of the 

"R" certificate holder that performed the 
construction portion of the alteration. The 
construction organization shall complete 
the Form R-2 provided by the design orga- 
nization, including the "Construction Cer- 
tificate" section. An Inspector shall indicate 
that the work complies with the applicable 
requirements of this code by completing 
and signing the "Certificate of Inspection" 
section of the form. When no construction 
work is performed (e.g., a re-rating with no 
physical changes), the "R" certificate holder 



B6 



NATIONAL BDARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



responsible for the design shall prepare the 
Form R-2, including the gathering and at- 
taching of supporting reports. 

A09 d) The following shall be attached to and 
become a part of completed Form R-2: 

1 ) For ASME boilers and pressure vessels, 
a copy of the original Manufacturer's 
Data Report, when available; 

2) Form R-3, Report of Fabricated Parts or 
Manufacturer's Partial Data Reports; 
and 

3) For other than ASME, the manufactur- 
er's reports (i.e., reports required by 
the original code of construction, etc.), 
when available. 



5.3 DISTRIBUTION OF FORM R-1 

a) Legible copies of completed Form R-1, 
together with attachments, shall be distrib- 
uted to the owner or user, the Inspector, the 
Jurisdiction, if required, and the Authorized 
Inspection Agency responsible for inservice 
inspection. 

b) Distribution of Form R-1 and attachments 
shall be the responsibility of the organiza- 
tion performing the repair. 



tion agency responsible for the inservice 
inspection of the pressure-retaining item, 
the owner-user, the "R" certificate holder 
responsible for design, and the Jurisdiction, 
if required. 



5.5 REGISTRATION OF "R" FORMS 

— GENERAL 

a) Organizations performing repairs or al- 
terations under an "R" stamp program may 
register such repairs or alterations with the 
National Board. 

b) It should be noted that some Jurisdictions 
may require registration of repairs and al- 
terations with the National Board. 

c) For those "R" Forms not registered with 
the National Board, the organization per- 
forming repairs or alterations shall retain a 
copy of the "R" Form on file for a minimum 
period of five years. 



5.5.1 



REGISTRATION FOR REPAIRS 



Form R-1 may be registered with the National 
Board as noted above. 



5.5.2 REGISTRATION FOR 

ALTERATIONS 



5.4 DISTRIBUTION OF FORM R-2 

a) Distribution of completed Form R-2 shall 
be the responsibility of the "R" certificate 
holder that performed the construction por- 
tion of the alteration. When no construction 
work is performed (e.g., a re-rating with no 
physical changes), the "R" certificate holder 
responsible for the design shall distribute 
the form. 

b) Legible copies of the completed Form R-2, 
together with attachments, shall be distrib- 
uted to the Inspector, the authorized inspec- 



b) 



If the pressure-retaining item is originally 
registered with the National Board, an 
original Form R-2, together with attach- 
ments, shall be registered with the National 
Board. 

If the item was not registered with the 
National Board, one original Form R-2, 
together with attachments, may be regis- 
tered with the National Board or retained 
as required by 5.5. 



sv 



NATIONAL BDARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



5.5.3 REGISTRATION FOR FIBER- 

REINFORCED VESSELS 

Organizations performing repairs or alterations 
under an "R" stamp program shall register 
such repairs or alterations with the National 
Board. 



5.5.4 REGISTRATION FOR NUCLEAR 

REPAIR/REPLACEMENT 
ACTIVITIES 

Organizations performing repair/replacement 
activities under the "NR" stamp program shall 
register forms with the National Board. 



5.5.5 REGISTRATION FOR GRAPHITE 

VESSELS 

Organizations performing repair/replacement 
activities under the "R" stamp program shall 
register such repairs or alterations with the 
National Board. 



5.6 



FORM "R" LOG 



The "R" certificate holder shall maintain a 
single, sequential log of "R" Form numbers as- 
signed for NBIC Report Forms (e.g., R-1, R-2, 
and R-3) that are registered with the National 
Board. 



A07 5.7 



A07 5.7.1 



STAMPING REQUIREMENTS 
FOR REPAIRS AND 
ALTERATIONS 



GENERAL 



A07 The stamping of or attaching of a nameplate 
to a pressure-retaining item shall indicate that 
the work was performed in accordance with 
the requirements of this Code. Such stamping 
or attaching of a nameplate shall be done only 
with the knowledge and authorization of the 
Inspector. The "R" certificate holder responsible 
for the repair or the construction portion of the 



alteration shall apply the stamping. For a re- 
rating where no physical changes are made to 
the pressure-retaining item, the "R" certificate 
holder responsible for design shall apply the 
stamping. 

5.7.2 STAMPING REQUIREMENTS 

FOR REPAIRS 

a) Pressure-retaining items repaired in accor- 
dance with the NBIC shall be stamped as 
required by this section. 

b) Subject to the acceptance of the Jurisdic- 
tion and the concurrence of the Inspector, 
nameplates and stamping may not be re- 
quired for routine repairs (see 3.3.2). In all 
cases, the type and extent of repairs neces- 
sary shall be considered prior to waiving 
the requirement. 

c) Stamping or nameplate shall be applied ad- A09 
jacent to the original manufacturer's stamp- 
ing or nameplate. A single repair nameplate 

or stamping may be used for more than one 
repairto a pressure-retaining item, provided 
each is carried out by the same certificate 
holder. The date of each repair, correspond- 
ing with the date on associated Form R-1, 
shall be stamped on the nameplate. 



5.7.3 STAMPING REQUIREMENTS 

FOR ALTERATIONS 

Pressure-retaining items altered in accordance 
with this code shall have a nameplate or stamp- 
ing applied adjacent to the original manufac- 
turer's stamping or nameplate in accordance 
with this section. For an alteration where physi- 
cal changes are made to the pressure-retaining 
item, the "R" certificate holder responsible 
for the construction portion of the alteration 
shall apply the stamping or nameplate. For an 
alteration where no physical changes are made 
to the pressure-retaining item (e.g., a re-rating) 
the "R" certificate holder, assuming responsi- 
bility for the design, shall apply the stamping 
or nameplate. 



SB 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



A09 5.7.4 STAMPING REQUIREMENTS 

FOR PARTS 

Stamping or nameplate shall be applied in a 
conspicuous location on the part. 

5.7.5 SPECIFIC REQUIREMENTS FOR 

STAMPING AND NAMEPLATES 

a) Required data shall be in characters of 
at least 5/32 in. (4 mm) high, except that 
characters for pressure relief valve repair 
nameplates may be smaller. Markings may 
be produced by casting, etching, emboss- 
ing, debossing, stamping, or engraving. 
The selected method shall not result in any 
harmful contamination of or sharp discon- 
tinuities to the pressure-retaining item. See 
Figures 5.7.5-a thru 5.7.5-g. 

b) The National Board code symbols ("R","VR", 
and "NR") are to be stamped; Do Not Em- 
boss. 

c) Stamping directly on items, when used, 
shall be done with blunt-nose continuous 
or blunt-nose interrupted dot die stamps. 
If direct stamping would be detrimental to 
the item, required markings may appear on 
a nameplate affixed to the item. 

d) The certificate holder shall use its full name 
as shown on the Certificate of Authoriza- 
tion or an abbreviation acceptable to the 
National Board. 

e) The letters "RP" shall be stamped below the 
"R" symbol stamp to indicate organizations 
accredited for performing repairs or altera- 
tions to fiber-reinforced plastic items. 

f) The letter "G" shall be stamped below the 
"R" symbol stamp to indicate organizations 
accredited for performing repairs or altera- 
tions to graphite pressure equipment. 



5.8 REMOVAL OF ORIGINAL 

STAMPING OR NAMEPLATE 



A09 



If it becomes necessary to remove the original 
stamping, the Inspector shall, subject to the 
approval of the Jurisdiction, witness the making 
of a facsimile of the stamping, the obliteration 
of the old stamping, and the transfer of the 
stamping to the new item. When the stamping 
is on a nameplate, the Inspector shall witness 
the transfer of the nameplate to the new loca- 
tion. Any relocation shall be described on the 
applicable NB1C "R" Form. The re-stamping or A07 
replacement of a code symbol stamp shall be 
performed only as permitted by the governing 
code of construction. 



5.9 



5.9.1 



STAMPING REQUIREMENTS 
FOR PRESSURE RELIEF DEVICES 



NAMEPLATES 



Proper marking and identification of tested or 
repaired valves is critical to ensuring accep- 
tance during subsequent inspections, and also 
provide for traceability and identification of any 
changes made to the valve. All operations that 
require the valve's seals to be replaced shall 
be identified by a nameplate as described in 
5.9.2 or 5.9.4. 



5.9.2 



REPAIR NAMEPLATE 



When a pressure relief valve is repaired, a 
metal repair nameplate stamped with the in- 
formation required below shall be securely 
attached to the valve adjacent to the original A07 
manufacturer's stamping or nameplate. If not 
mounted directly on the valve, the nameplate 
shall be securely attached so as not to interfere 
with valve operation and sealed in accordance 
with the quality system. A07 

a) Prior to attachment of the repair nameplate, 
the previous repair nameplate, if appli- 
cable, shall be removed from the repaired 
valve. 



89 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



b) As a minimum, the information on the valve 
A09 repair nameplate (see Figure 5.7.5-e) shall 
include: 

1) The name of the repair organization 
preceded by the words "repaired by"; 

2) The "VR" repair symbol stamp and the 
"VR" certificate number; 

3) Unique identifier (e.g., repair serial 
number, shop order number, etc.); 

4) Date of repair; 

5) Set pressure; 

6) Capacity and capacity units (if changed 
from original nameplate due to set pres- 
sure or service fluid change); 

7) Type/Model number (if changed from 
original nameplate by a conversion. See 
Supplement S7.2); and 

8) When an adjustment is made to correct 
for service conditions of superimposed 
back pressure and/or temperature or the 
differential between popping pressure 
between steam and air (see 4.5.2), the 
information on the valve repair name- 
plate shall include the: 

a. Cold Differential Test Pressure 
(CDTP); and 

b. Superimposed Back Pressure (BP) 
(only when applicable). 



5.9.3 CHANGES TO ORIGINAL 

PRESSURE RELIEF VALVE 
NAMEPLATE INFORMATION 

a) If the set pressure is changed, the set pres- 
sure, capacity, and blowdown, if applica- 
ble, on the original nameplate or stamping 
shall be marked out but left legible. The 
new capacity shall be based on that for 



which the valve was originally certified. 

b) If the service fluid is changed, the capacity, 
including units, on the original nameplate 
or stamping shall be marked out but left 
legible. The new capacity shall be based 
on that for which the valve was originally 
certified, or if a conversion has been made, 
as described in S7.2 on the capacity certi- 
fication for the valve as converted. 

c) If the Type/Model number is changed, the 
Type/Model number on the original name- 
plate shall be marked out but left legible. 

d) If the blowdown is changed, the blowdown 
on the original nameplate or stamping shal I 
be marked out but left legible. The new 
blowdown may be based on the current 
ASME Code requirements. 

e) Incorrect information on the original man- 
ufacturer's nameplate shall be marked out 
but left legible. Corrected information shall 
be indicated on the repair nameplate and 
noted on the document as required by the 
quality system. A07 



5.9.4 



TEST ONLY NAMEPLATE 



a) Where a valve has been tested and adjusted, 
as permitted by S7.1 0.1 , but not otherwise 
repaired, a "Test Only" nameplate shall be 
applied that contains the following informa- 
tion: 

1 ) Name of responsible organization; 

2) Date of test; 

3) Set Pressure; and 

4) Identification, such as "Test Only." 

b) A "Test Only" nameplate is also recom- 
mended when periodic testing has been 
performed, even when no adjustments have 
been made, for the purpose of identifying 
the date the valve was tested. 



su 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



c) The existing repair nameplates, if appli- 
cable, shall not be removed during such 
testing. 



5.9.5 REPLACEMENT OF ILLEGIBLE 

OR MISSING NAMEPLATES 

a) Illegible Nameplates 

When the information on the original 
manufacturer's or assembler's nameplate or 
stamping is illegible, buttraceability can be 
confirmed, the nameplate or stamping will 
be augmented by a nameplate furnished 
by the "VR" stamp holder stamped "Dupli- 
cate." It shall contain all information that 
originally appeared on the nameplate or 
valve, as required by the applicable section 
of the ASME Code, except the "V," "HV," or 
"UV" symbol and the National Board mark. 
The repair organization's nameplate, with 
the "VR" stamp and other required data 
specified in 5.9.2, will make the repairer 
responsible to the owner and the Jurisdic- 
tion that the information on the duplicate 
nameplate is correct. 

b) Missing Nameplates 

When the original valve nameplate is 
missing, the repair organization is not 
authorized to perform repairs to the valve 
under the "VR" program, unless positive 
identification can be made to that specific 
valve and verification that the valve was 
originally stamped with an ASME "V" or 
"UV" symbol or marked with an ASME 
"HV" symbol. Valves that can be positively 
identified will be equipped with a duplicate 
nameplate, as described in this section, in 
addition to the repairer's "VR"-stamped 
nameplate. The repairer's responsibilities 
for accurate data, as defined in 5.9.5(a) 
(Illegible Nameplates), shall apply. 

c) Marking of Original Code Stamp 

When a duplicate nameplate is affixed to 
a valve, as required by this section, it shall 
be marked "Sec. I," "Sec. IV," or "Sec. VIII," 
as applicable, to indicate the original ASME 
Code stamping. 



5.10 ALTERNATIVE MARKING AND 

STAMPING FOR GRAPHITE 
PRESSURE EQUIPMENT 

a) General Requirements 

1) This procedure may be used in lieu of 
the stamping and nameplate require- 
ments defined in this section. 

2) The required data as defined in this 
section shall be 5/32 in. (4 mm) high, 
minimum. 

3) The National Board code symbol ("R") 
shall be used to make the impression 
in the cement. 

b) Application of the "R" Code Symbol 

1) The graphite surface shall be clean and 
smooth. 

2) Apply a thin coating of cement onto the 
Code part. The cement should have the 
consistency of toothpaste. 

3) Apply sufficient heat to the cement so 
that it begins to form a skin. 

4) Apply a coating of a thinned release 
agent, such as "ANTISEIZE," to the tip 
of the "R" stamp with a brush. 

5) Press the coated stamp all the way to the 
bottom of the cement and remove by 
pulling straight out before the cement 
hardens. 

6) Cure or heat the impression as re- 
quired. 

7) When cured, the part may be washed 
to remove any excess release agent. 

c) Application of characters directly to graphite 

1 ) Use a very thin template of a flexible 
material (stainless steel; flexible and 
easily cleaned). 



91 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



2) Place the template over a clean smooth 
surface. 

3) Hold the template securely and trowel 
over with approved cement to fill all of 
the template area. 

4) Carefully lift the template from the 
graphite part and examine the detail of 
the characters. 

5) If acceptable, cure the cement. 

6) If the characters are incorrect or dam- 
aged, wipe off the cement with a com- 
patible solvent and reapply. 

Note: The preceding methods can be 
applied jointly to identify the graphite 
part and to transfer the "R" stamp. 



5.11 STAMPING FOR FIBER- 

REINFORCED VESSELS 

The attaching of a nameplate to a repaired or 
altered vessel or tank shall indicate that the 
work was performed in accordance with the 
requirements of this Code. The attachment of a 
nameplate shall be done only with the knowl- 
edge and authorization of the Inspector. The 
certificate holder responsible for the repair or 
alteration shall apply the stamping nameplate. 
Required stamping and nameplate information 
A09 are shown in NBIC, Part 3, 5.7. 



5.11.1 REMOVAL OF ORIGINAL 

STAMPING OR NAMEPLATE 

If it becomes necessary to remove the original 
stamping, the Inspector shall, subject to the 
approval of the Jurisdiction, witness the making 
of a facsimile of the stamping, the obliteration 
of the old stamping, and the transfer of the 
stamping to the new item. When the stamping 
is on a nameplate, the Inspector shall witness 
the transfer of the nameplate to the new lo- 
cation. Any relocation shall be described on 
A07 the applicable NBIC form. The restamping or 



replacement of a code symbol stamp shall be 
performed only as permitted by the governing 
code of construction. 



5.11.2 



STAMPING FOR REPAIRS 



Pressure-retaining items repaired in accordance 
with the NBIC shall have a nameplate as re- 
quired by Section 5.7 Subject to the acceptance A09 
of the jurisdiction and the concurrence of the 
Inspector, nameplates may not be required for 
routine repairs. (See 5.7.2 [b]). In all cases, the 
type and extent of repairs necessary shall be 
considered prior to waiving the requirement. 



5.11.3 



STAMPING FOR ALTERATIONS 



The nameplate shall be applied in accordance 
with Section 5.7. The location of the nameplate A09 
shall be documented on the Form R-2. 



92 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



5.12 STAMPING REQUIREMENTS 

FOR YANKEE DRYERS 

a) Stamping is not required for repairs that do 
not affect the pressure-retaining capability 
of the Yankee shell, as indicated on the 
De-rate Curve, or other pressure-retaining 
parts, as indicated on the original Manu- 
facturer's Data Report. 

b) Stamping is required for repairs that do af- 
fect the pressure-retaining capability of the 
Yankee shell, as indicated on the De-rate 
Curve, or other pressure-retaining parts as 
indicated on the original Manufacturer's 
Data Report. 

c) Stamping is required for alterations as listed 
in Supplement 5.7.2 

d) Stamping, when required, shall meet the 
requirements for stamping in 5.7.3. The 
location of stamping shall be described in 
the "remarks" section of Form R-2. 



FIGURE 5.7.5-b 

Required markings for alterations, with use of Na- 
tional Board Form R-2 

ALTERED BY 



R 

4. y 



CERTIFICATE HOLDER 



AT 



Minimum Required Relieving Capacity 



NATIONAL BOARD "R" 
CERTIFICATE NUMBER 



DATE ALTERED 



A09 



FIGURE 5.7.5-c 

Required markings for re-ratings, with use of National 
Board Form R-2 

RE-RATED BY 



fC o^ 



CERTIFICATE HOLDER 



P.S.I. 



Minimum Required Relieving Capacity 



NATIONAL BOARD "R" 
CERTIFICATE NUMBER 



DATE ALTERED 



A09 



FIGURE 5.7.5-a 

Required markings for repairs, with use of National 
Board Form R-1 



REPAIRED BY 






NATIONAL BOARD "R" 
CERTIFICATE NUMBER 



CERTIFICATE HOLDER 



DATE REPAIRED 



*NOTE: A o9 

a) Not required when the scope of work does 
not change the Minimum Required Reliev- 
ing Capacity. 

b) If the line identifying Minimum Required 
Relieving Capacity is represented on the 
nameplate and the scope of work does not 
affect the Minimum Required Relieving 
Capacity, the line shall be"X'd" to represent 
"no change". 

c) Minimum Required Relieving Capacity may 
be abbreviated to M.R.R.C. 



93 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



A09 



FIGURE 5.7.5-d 

Required markings for parts fabricated by welding 

with use of National Board Form R-3 

PART 



R 

4. y 



NATIONAL BOARD "R" 
CERTIFICATE NUMBER 



CERTIFICATE HOLDER 



M.A.W.P. 



MANUFACTURER'S SERIAL NO. 



FIGURE 5.7.5-g 

Required markings for repair or replacement of 
nuclear pressure relief valves 



A09 



m w 



NATIONAL BOARD 
CERTIFICATE NOS. 



REPAIR □ 

REPLACEMENT Q 



CERTIFICATE HOLDER 
COMPLETED IN ACCORDANCE WITH ASME SECTION XI 



EDITION 



ADDENDA CODE CASE(S) 



SET PRESSURE 



CAPACITY 
(IF CHANGE IN 
SET PRESSURE) 



DATE OF REPAIR OR REPLACEMENT 



A09 



FIGURE 5.7.5-e 

Required markings for repair of ASME/National Board 
"V," "UV," and "HV"-stamped pressure relief valves 

REPAIRED BY - 



w 



NATIONAL BOARD "VR" 
CERTIFICATE NUMBER 



CERTIFICATE HOLDER 
(1) 



TYPE/MODEL NUMBER 



SET PRESSURE 



(D 



(1) 



CDTP 



CAPACITY 



(D 



REPAIR IDENTIFICATION 



DATE REPAIRED 



Note 1: To be indicated on!y when 
changed. 



5.13 REPAIR AND ALTERATION 

FORMS AND GUIDELINES FOR 
COMPLETING FORMS 



A09 



FIGURE 5.7. S-i 

Required markings for nuclear repairs or 
replacements 



rsR 



NATIONAL BOARD "NR* 
CERTIFICATE NUMBER 



REPAIR □ 

REPLACEMENT [J 



CERTIFICATE HOLDER 



COMPLETED IN ACCORDANCE WITH ASME SECTION XI 



EDITION ADDENDA CODE CASE(S) 



DATE OF REPAIR OR REPLACEMENT 



94 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



5.13.1 FORM R-1, REPORT OF REPAIR 



FORM R-1 REPORT OF REPAIR 

in accordance with provisions of the National Board Inspection Code 



1 . Work performed by 



® ® 

(name of repair organization) (Form R No.) 

(53) 



(PO No., Job No., etc.) 



Ownpr w 




(name) 


(address) 

. Location of installation _ 


© 


(name) 



(address) 

— ^ Namp of orip-inal mptmifartiirpr ^ 



4. Unit identification i^i Name of original manufacturer 

(boiler, pressure vessel) _ 

5. Identifying nos.:_® _® ,__ © ® ® 

J ° (mfg. serial no ) (National Board No.) (Jurisdiction No.) (other) (year built) 

(g) @) 



6. NBIC Edition / Addenda: 



(edition) (addenda) 

S) @ 



(name/ section / division) (edition/addenda) 



Original Code of Construction for Item: 

Construction Code Used for Repair Performed: i^j ^ 

(name/ section /division) (edition/ addenda) 

7. Repair Type:^ I I Welded I I Graphite Pressure Equipment I I FRP Pressure Equipment 

8. Description of work: SBJ 

(use supplemental sheet, Form R-4, if necessary) 



. Pressure Test, if applied W psi MAWP J§M psi 



9. Replacement Parts. Attached are Manufacturer's Partial Data Reports or Form R-3s properly 
completed for the following items of this report: 



(14; 



(name of part, item number, data report type, mfg. name, and identifying stamp) 



10. Remarks :_J£ 



CERTIFICATE OF COMPLIANCE 

(16) 
I, — i=^ , certify that to the best of my knowledge and belief the statements in this report are 

correct and that all material, construction, and workmanship on this Repair conforms to the National Board Inspection Code. 

National Board "R" Certificate of Authorization No. Cffl expires on Oj) , 

Date^H , 1 S~d frl " " 



(name of repair organization) (authorized representative) 



CERTIFICATE OF INSPECTION 

(22) 
1/ — ^ , holding a valid Commission issued by The National Board of Boiler and Pressure 

Vessel Inspectors and certificate of competency, where required, issued by the Jurisdiction of (23) 

and employed by J24j of (25) 



have inspected the work described in this report on A2§) , and state that to the best of my knowledge 

and belief this work complies with the applicable requirements of the National Board Inspection Code. 

By signing this certificate, neither the undersigned nor my employer makes any warranty, expressed or implied, concerning 

the work described in this report. Furthermore, neither the undersigned nor my employer shall be liable in any manner for 

any personal injury, property damage or loss of any kind arising from or connected with this inspection. 

Date (& , Signed __(§) Commissions J2g) 

(inspector) (National Board and Jurisdiction No.) 

This lorm may be obtained from The National Board of Boiler and Pressure Vessel Inspectors, 1 055 Crupper Ave., Columbus, OH 43229 NB-66 Rev. 1 1 

95 ~ 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



5.1 3.2 FORM R-2, REPORT OF ALTERATION 



FORM R-2 REPORT OF ALTERATION 
in accordance with provisions of the National Board Inspection Code 



la. Construction performed by 



m. 



(name of "R" organization responsible (or construction) 



;53; 



(address) 

lb. Design performed by (l , 



(PO No., job No., etc.) 



(name of "R" organization responsible for design] 



(Form "R" No.) 



(address) 

2. Owner ( 3 y 



(PO No., Job No., etc.) 



(address) _ 

3. Location of installation (4) 



(name) 



(address) 

4. Unit identification (5) 



5. Identifying nos.: (j) 



(boiler, pressure vessel) 



Name of original manufacturer (6 y 



QL 



(mfg. serial no.) (National Board No.) 

6. NBIC Edition /Addenda: J5) 



(jurisdiction no.) (other) 

(io) 



(year built) 



(edition) 

Original Code of Construction for Item: Q-V 

(name /section /division 

Construction Code Used for Alteration Performed: (ji 



(edition/ addenda) 



(name/ section/ division) 



M. 



(edition/ addenda) 



7a. Description of construction work: v 12 ) 



(use supplemental sheet, Form R-4, if necessary) 



7b. Description of design scope: 0- 2 ) 



(use supplemental sheet. Form R-4, if necessary) 



© 



. psi 



MAWP_ 



.541 



.pa 



Pressure Test, if applied 

8. Replacement Parts. Attached are Manufacturer's Partial Data Reports or Form R-3s properly 
completed for the following items of this report: 

(S> 

(name of pari, item number, data report type, mfg. name, and identifying mark) 



9. Remarks: (35) 



This form may be obtained from The National Board of Boiler and Pressure Vessel Inspectors, 1 055 Crupper Ave., Columbus, OH 43229 



NB-229 Rev.4 



96 



NATIONAL BOARD INSPECTION CODE * PART 3 — REPAIRS AND ALTERATIONS 



Form R-3 (back) 



& 



(Form "R" No.) 



CERTIFICATE OF COMPLIANCE 

I, (16) , certify that to the best of my knowledge and belief the statements in this report are 

correct and that all material, fabrication, construction, and workmanship of the described parts conforms to the National 
Board Inspection Code and standards of construction cited. 

National Board "R" Certificate of Authorization No Q_7) expires on (18) , 

_, i§) Signed jg) 



Datei^l 



e of "R" Certificate Holder) (authorized representative) 



CERTIFICATE OF INSPECTION 

_,holding a valid Commission issued by The National Board of Boiler and Pressure 



Vessel Inspectorsiind certificate of competency issued by the jurisdictijjn of \~£) and 

employed by (24) of J25) 



have inspected the parts described in this report on (26) , and state that to the best of my knowledge and 

belief the parts comply with the applicable requirements of the National Board Inspection Code. 

By signing this certificate, neither the undersigned nor my employer makes any warranty, expressed or implied, concerning 

the work described in this report. Furthermore, neither the undersigned nor my employer shall be liable in any manner for 

any personal injury, property damage or loss of any kind arising from or connected with this inspection. 

Date x^L) , Signed (27 I Commissions (28) 



(inspector) (National Board and Jurisdiction No.) 



99 



NATIONAL BOARD INSPECTION CODE ■ PART 3 — REPAIRS AND ALTERATIONS 

5.1 3.4 FORM R-4, REPORT SUPPLEMENTARY SHEET 

FORM R-4 REPORT SUPPLEMENTARY SHEET 
in accordance with provisions of the National Board Inspection Code 



1. Work performed hy OJ 1 ^) 



(name) 



2. Owner 



G>»@ @ 



(name) 



® (®) 



(Form "R" referenced) 
(TO No., Job No v etc.) 



(address) 

3. Location of installation . 



(name) 



(address) 

Reference 

Line No. Continued from Form R-J2L 

_M (S) 



Date. 



(19) 



Date @ 



Signed . 



(authorized representative) 



Signed _H2_ 



Name^M. 



(Name of "R" Certificate Holder) 



Commissions Q s ) 



(inspector) (National Board and Jurisdiction No) 

This form may be obtained from The National Board of Boiler and Pressure Vessel Inspectors, 1 055 Crupper Ave., Columbus, OH 43229 NB-231 Rev. 2 

1 DD 



A09 
A09 




Part 3, Section S 

Repairs and Alterations — 

Supplements 



1 D9 



NATIONAL BOARD INSPECTION CODE 8 PART 3 — REPAIRS AND ALTERATIONS 

PART 3, SECTION 6 

REPAIRS AND ALTERATIONS — SUPPLEMENTS 



SUPPLEMENT 1 b) Special jurisdictional approval may be re- 

STEAM LOCOMOTIVE FIRETUBE quired prior to starting welding activity on 

BOILER REPAIRS locomotive boilers. 



S1.1 



GENERAL REQUIREMENTS 



S1.1.3 



MATERIALS 



SI .1.1 FEDERAL RAILROAD 

ADMINISTRATION (FRA) 

The FRA rules for steam locomotive boilers 
are published in the Code of Federal Regula- 
tions (CFR) 49CFR Part 230 Dated November 
17,1 999. ,1 All locomotives under FRA jurisdic- 
tion are documented on FRA Form 4 as defined 
in 49CFR Part230.This document is the formal 
documentation of the steam locomotive boiler 
and is required to be completed prior to the 
boiler being placed in service. This document 
shall be used as the data report for the boiler, 
applicable to all repairs and alterations per- 
formed. National Board "R" certificate holders 
shall document their repairs and/or alterations 
on National Board Forms R-1 or R-2. These 
reports shall be distributed to the owner-user of 
the boiler, who is required to incorporate them 
into a FRA Form 1 9, which becomes an attach- 
ment to the FRA Form 4. The design margin for 
all such repairs or alterations shall not be less 
than four based on ultimate tensile strength of 
the material. 



a) The older steels used in riveted construc- 
tion were frequently rimmed steels, high in A07 
carbon, sulfur, phosphorus and hydrogen. 
The older steels were not melted to a fine 
grain practice and will typically have poor 
toughness properties. 

b) If welding is to be used to repair a pressure- 
retaining item that was manufactured using 
riveted construction, the repair organiza- 
tion should perform a chemical composi- A07 
tion analysis on the steel plate base metal 
and rivet material to determine weldabi I ity. 
Specific quantities of carbon, manganese, 
sulfur, phosphorus, and aluminum shall 

be identified and included in the analysis. 
The result of the analysis shall be accept- 
able to the Inspector and Jurisdiction when 
required. 



S1 .1 .2 REQUIREMENTS FOR WELDING 

ACTIVITIES 

a) Before performing any welding activities, 
consideration shall be given to ensure the 
weldability of locomotive boiler materials. 



1 1 Steam locomotive inspection and maintenance standards, 
which is now codified at 49 CFR Part 230, may be obtained at 
the FRA Website. The final mleatwww.fra.dot.gov/downloads/ 
counsel/fr/slfr.pdf. 



1 1 D 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



S1 .1 .3.1 MATERIAL LIST FOR STEAM 
LOCOMOTIVE BOILERS 

The following list is intended as a basic guide- 
line only and covers basic carbon steel and 
some alloy steel material specifications. Other 





Application 

Boiler Tubes & 
Flues, Arch Tubes 
Superheater Units 


Specification 

SA-1 78 Grade A, 
SA-192, SA-210 




Boiler & Firebox Plate, 
Pressure Retaining Plate 


SA-285 Grade C, 
SA-515, SA-516, 
SA-203, SA-204 


A09 


Welded Staybolts 


SA-675, SA-36, 
SA-31 Grade B 


A09 


Threaded Staybolts 


SA-31 Grade A 
SA-675 with a tensile 
strenght of 47,000 psi 
to 65,000 psi inclusive 




Staybolt Sleeves and 
Caps 


SA-105 Forging, 

SA-675 




Boiler Braces 


SA-675, SA-36 




Rivets 


SA-675, 
SA-31 




Forged Parts & Fittings 


SA-105, SA-1 81 




Pressure-Retaining 
Steel Castings 


SA-216, A-217 




Hollow Cylindrical 
Pressure-Retaining 
Parts 


SA-105 Forgings, 
SA-675 Bar Stock 




Superheater Unit Bolts 

& Nuts 


Bolts -SA-1 93, 
Nuts - SA-1 94 


A08 


Pipe Flanges 


SA-1 81, SA-105 



alloy materials may be available for these 
applications if necessary. 

a) SA-516 steel is recommended for firebox 
repairs. It is a fine grain steel that accepts 
flanging and bending with less tendency to 
crack than coarse grain steels such as SA- 
515 or SA-285 Grade C. Coarse grain steels 
have, on occasion, been found to crack or 
split after complicated flanging, bending, 
and forming. 



b) SA-36 shall not be used to make any pres- 
sure-retaining part such as shells, staybolt 
sleeves, or caps. 

c) When rivets are made from SA-675, the fin- 
ished rivets must meet the physical require- 
ments of the original rivet specification or 
SA-31 Grade A or B. 

d) When staybolt material tensile strength 
is stronger than that of the firebox sheets, 
the firebox sheets deflect instead of the 
staybolts, which can result in the sheets 
developing cracks and leaking staybolts. In 
addition, high tensile strength steels are dif- 
ficult to drive. Maximum allowable tensile A09 
strength shall be 7,500 psi (51 .71 MPa). 



SI. 1.4 FORMULA AND 

CALCULATIONS FOR STEAM 
LOCOMOTIVE BOILERS 

a) Most steam locomotive boilers were manu- 
factured in the first half of the 20 th century 
or before. The calculations, formula, and 
shop practices used are now distant history 
and quite difficult to obtain. The rules for 
riveted construction were last published by 
ASME in Section I Code, 1971 Edition. 12 

b) This Supplement herein, is based in part on 
the ASME Code, Section III, 1952 Edition, 12 
which was the last published edition of 
the Steam Locomotive Code. The railroad 
industry has attempted to collect the old 
formula and some shop practices. These 
have been published by The Engineering 
Standards Committee for Steam Locomo- 
tives, Inc. (ESC) as Compendium, Volume 
1, Compilation of Calculations. 13 



12 This Code is available from the National Board. 
1 3 Copies of The Engineering Standards Committee for Steam 
Locomotives, Inc., Compendium, Volume i, Compilation of 
Calculations, may be obtained from the Strasburg Rail Road, 
P.O. Box 96, Strasburg, PA 17579, 717.687.8421. 



1 1 1 



NATIDNAL BOARD INSPECTION CDDE • PART 3 



REPAIRS AND ALTERATIONS 



S1.2 LOCOMOTIVE FIRETUBE 

BOSLER REPAIRS 

S1 .2.1 REPAIR OF STAYBOLT HOLES 



Staybolt holes may be repaired by welding, 
reaming, or retapping to a larger size or by 
installing a flush patch. 

If the staybolt hole was threaded and is to 
be repaired by welding, the threads shall 
be removed prior to welding. 



b) 



S1.2.2 THREADED STAYBOLTS 

(SEE FIGURE S1.2.2) 

a) All threaded staybolts shall have either 1 1 - 
or 12-thread pitch. Staybolt threads shall 
have a good close fit in sheets. Changing 
the staybolt thread pitch from 11 to 12 or 
the reverse shall be considered a repair. 

b) All staybolts shorter than 8 in. (200 mm) 



in length shall have telltale holes. Staybolt 
telltale holes in existing bolts shall be 3/1 6 
in. (5 mm) to 7/32 in. (5.5 mm) in diameter 
and at least 1-1/4 in. (32 mm) deep in the 
outer end. When staybolts 8 in. (200 mm) 
or less in length are replaced, they shall be 
replaced with staybolts that have a telltale 
hole 3/1 6 in. (5 mm) to 7/32 in. (5.5 mm) 
in diameter their entire length or with ones 
that have a 3/1 6 in. (5 mm) to 7/32 in. (5.5 
mm) diameter hole in each end, drilled a 
minimum of 1-1/4 in. (32 mm) deep. On 
reduced body staybolts the telltale hole 
shall extend beyond the fillet and into the 
reduced section of the staybolt. 

Ball socket-type flexible staybolts may 
have telltale holes that extend from the 
threaded end of the bolt into the bolt head 
for a distance of 1/3 the spherical bolt head 
diameter. 

c) Telltale holes shall be reopened after driv- 
ing. 




1 1 2 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



FIGURE S1.2.3-d 

Half Sleeve Repair Procedure for Damaged 

Ball Socket Flexible Staybolt Welded Sleeve 

half sleeve 

I 



V 

A 





thread for standard flexible 
staybolt cap and gasket 



this surface machined for 
full penetration weld joint 




FIGURE S1.2.3-e 

Half Sleeve Repair Procedure for Damaged 

Ball Socket Flexible Staybolt Welded Sleeve 



half sleeve 
installed with full 
penetration weld 




FIGURE S1 .2.4 

Seal Welded Stay bolts 



staybolt head seal welded before driving 





staybolt head seal welded after driving 



1 1 5 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



S1 .2.4 SEAL WELDED STAYBOLTS 

(SEE FIGURE S1 .2.4) 

a) Replacement threaded staybolts may be 
seal welded before or after driving. 

b) Existing threaded staybolts that leak shall 
be repaired and may be seal welded. When 
used, seal welding shall not be the sole 
means of repair. 



7/32 in. (5.5 mm) in diameter and at least 
1-1/4 in. (32 mm) deep in the outer end. 
On reduced body staybolts, the telltale hole 
shall extend beyond the fillet and into the 
reduced section of the staybolt. Staybolts 
should have through telltale holes, which 
are preferred. Ball socket-type flexible stay- 
bolts may have telltale holes that extend A07 
from the welded end of the bolt into the 
bolt head for a distance of 1 /3 the spherical 
bolt head diameter. 



S1.2.5 WELDED INSTALLATION OF 

STAYBOLTS 

a) The installation of unthreaded staybolts us- 
ing full penetration welds is permissible. 

b) All staybolts shorter than 8 in. (200 mm) 
in length shall have telltale holes. Telltale 
hole diameter shall be 3/16 in. (5 mm) to 



Where necessary for boiler expansion, ball 
socket-type flexible staybolts shall be posi- 
tioned in such a manner as to not interfere 
with boiler expansion. Where individual 
bolts are replaced, care should be taken to 
assure that the stress load of the new bolt 
is compatible to the loading of adjacent 
bolts. 



A09 



FIGURE S1.2.6-a 

Diagonal Braces, Gusset Braces, and Throat Sheet/Tubesheet Braces 






diagonal brace 



pin-type diagonal brace 



solid-type brace 




throat sheet/tubesheet brace 




usset brace 



1 1 6 



NATIDNAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



A09 



FIGURE S1.2.6-B 



DIAGONAL BRACE ENDS 



Q_ 




Loop-Type End 



rrr 



it 



FIGURE S1 .2.6.1 -a 

GIRDER STAY 



A09 



_*_ — Girder Slay 

! i! i i ! i 
I I I I I I 




. -.■■\' t /..v. i /.\ i . i /..M. l '/...Y 




Side Sheet or 

Tube Sheet 



/ 








Thimble 
or Spacer 



Q 



Straight Thread 
Crown Stay 



A09 



FIGURE S1.2.6.1-b 



CROWN BAR WITH SLING STAYS 



Crown Bolt with Nut 







W 

J 



t7 



Crown Sheet 




ft 



FIGURE S1.2.6.2-a 



EYE-TYPE SLING STAY 




4 



-~P ^ ,.< ^Eye Brackcl 




A09 



1 1 6.1 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



A09 



FIGURE S1.2.6.2-b 



® 



o 



Sling Stay With 
Round Pin Holes 



r\ 







Sling Stay With 
Expansion Slot For Pin 



FIGURE S1.2.6.3-a 



EXPANSION STAY 




A 



Pin & Retainer **l 



Plain Hole 

In Bracket 



Expansion Stay ■ > 



Crown Sheet 




ISVwww w^fJ 



zztefezzzza. 



A09 



A09 



FIGURE S1.2.6.3-b 



BALDWIN-TYPE EXPANSION STAY 




^C 



i. 



\ 



Plain Hole 
In Bracket 



Firebox Crown Sheet 



ZZa 



^T7im7T7% 



FIGURE S1.2.8 
Patch Bolts 



typical patch bolt 




typical patch bolt application 




1 1 S.2 



NATIONAL BOARD INSPECTION CODE e PART 3 



REPAIRS AND ALTERATIONS 



Note: Some locomotive boiler designs 
positioned the bolts by backing the bolt 
head away from the sleeve socket bottom 
a certain amount. 

d) Installation of different diameter staybolts 
shall be considered a repair. 



S1 .2.6 DIAGONAL BRACES, GUSSET 

BRACES, AND THROAT SHEET/ 
TUBESHEET BRACES 
A09 (SEE FIGURES S1 .2.6 a) & S1 .2.6 b)) 

a) Loose or damaged braces shall be repaired 
or replaced. 

b) Only steel braces may be repaired by weld- 
ing. All such welds shall be full penetration. 
Wrought iron braces shall not be repaired 
by welding. When repairs or alterations are 
completed, the tightness and condition of 
the braces and their staybolts, rivets, clev- 
ises, eyes, and pins shall be verified. 

A09 c) For pins that are fitted with nuts, the pin 
length shall be sized so that all threads of 
the nut are engaged upon completion of 
installation. 



d) Replacement of diagonal stays having loop- A09 
type ends shall be considered a repair. 

S1.2.6.1 GIRDER STAYS AND CROWN A09 
BARS (SEE FIGURES S1 .2.6.1 a) & 
S1 .2.6.1 b)) 

a) When repairs or alterations are completed, 
the installation and condition of the crown 
bars or girder stays and all associated fit- 
tings, including stays, rivets, pins, washers, 
nuts, thimbles, spacers and retainers, shall 
be verified. 

b) Crown bars, girder stays and associated 
parts shall have the correct fit, alignment 
and bearing to the firebox and boiler 
sheets. 

c) Wrought iron crown bars and girder stays, 
and all associated fittings, shall not be re- 
paired by welding or application of riveted 
or bolted patches. 

d) Steel crown bars, steel girder stays and as- 
sociated steel brackets may be repaired or 
fabricated by welding. Welded repairs and 
components shall be made and examined 
in accordance with the ASME Boiler & 
Pressure Vessel Code, Section I. 



FIGURE S1.2.9.2-a 

Welded Installation of Arch Tube 




t = 

t = 

n 

t w = 
t = 



(y) 



t but not less 1 

n 

than 1/4 in. (6 mm) 




t but not less than 

n 

1/4 in. (6 mm 

i 




thickness of vessel shell or head, in. 

thickness of nozzle wall, in. 

dimension of partial penetration attachment welds (fillet, single bevel, or single J), measured as shown 

in Figure PW-16.1, in. 

not less than the smaller of 1/4 in. (6 mm) or 0.7 t min (inside corner welds may be further limited by a 

lesser length of projection of the nozzle wall beyond the inside face of the vessel wall) 

the smaller of 3/4 in. (19 mm) or the thickness of either of the weld parts joined by a fillet, single bevel, or 

single J-weld, in. 



1 1 7 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



e) Steel crown bars, steel girder stays and as- 
sociated steel brackets wasted or worn to 
less than 60% of original thickness shall 
not be repaired by weld buildup. 

f) On stays and pins that are fitted with nuts 
the stay or pin length shall be sized so that 
all threads of the nut are engaged upon 
completion of installation. 

g) When driving crown bolts the opposite bolt 
end shall be bucked or braced to prevent 
damaging the bolt threads in the firebox 
sheet. Bracing can be done several ways 
such as using a pneumatic holder-on or 
heavy steel bucking bar. The crown bolt 
head is to be driven in such a manner as to 
expand radially the crown bolt body and 
threads into the sheet prior to forming the 
head. Merely driving over the head is not 
acceptable. 

h) Telltale holes shall be reopened after driv- 
ing. 

i) Crown bolts shall have either 11 - or 12- 
th read pitch in the firebox sheets. Stay 
threads shall have good close fit in the fire- 
box sheet. Changing the thread pitch from 
11 to 1 2 or the reverse shall be considered 
a repair. 

A09 S1 .2.6.2 SLING STAYS (SEE FIGURES 
SI. 2.6.2 a) &S1. 2.6.2 b)) 

a) When repairs or alterations are completed, 
the installation and condition of the sling 
stays and all associated fittings, includ- 
ing brackets, rivets, pins, washers, nuts, 
thimbles and spacers, shall be verified. 

b) Sling stays and the associated parts shall 
have the correct fit, alignment and bear- 
ing to the crown bars, girder stays, firebox 
sheets and boiler sheets. 

c) On pins that are fitted with nuts the pin 
length shall be sized so that all threads of 
the nut are engaged upon completion of 
installation. 



d) Sling stays fabricated or repaired by weld- 
ing shall be welded and examined in ac- 
cordance with the ASME Boiler & Pressure 
Vessel Code Section I. 

e) Holes and slots in sling stays should have 
all edges rounded off. 

f) When driving sling stay eye brackets the 
opposite bracket end shall be bucked or 
braced to prevent damaging the threads. 
Bracing can be done several ways such as 
using a pneumatic holder-on or heavy steel 
bucking bar. The head of the sling stay eye 
bracket is to be driven in such a manner as 
to expand radially the body and threads into 
the sheet prior to forming the head. Merely 
driving over the head is not acceptable. 

g) All sling stays, nuts, and pins shall be 
retained mechanically or have mechani- 
cal retainers installed when renewed or 
replaced. 



S1 .2.6.3 EXPANSION STAYS (SEE FIG- 
URES SI .2.6.3 a) &S1. 2.6.3 b)) 



A09 



a) When repairs or alterations are completed, 
the installation and condition of the expan- 
sion stays and all associated fittings, includ- 
ing brackets, rivets, pins, washers, nuts, 
thimbles and spacers, shall be verified. 

b) Wrought iron expansion stay brackets shall 
not be repaired by welding. 

c) Expansion stays shall not be repaired by 
welding. 

d) Worn pin holes and expansion slots of steel 
expansion stay brackets may be repaired by 
welding. 

e) On stays and pins that are fitted with nuts 
the stay or pin length shall be sized so that 
all threads of the nut are engaged upon 
completion of installation. 

f) Stay length shall be sized so the length of 
the stay projecting through the sheet is not 
less than 1/8" and is sufficient to produce 



1 1 B 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



a full head after driving. 

g) Stays shall have either 11 - or 12- thread 
pitch. Stay threads shall have good close fit 
in the sheet. Changing the thread pitch from 
1 1 to 1 2 or the reverse shall be considered 
a repair. 

h) Installation of expansion stays that have a 
different diameter in the firebox sheet shall 
be considered a repair. 

i) Installation of expansion stays that have a 
different diameter in the bracket shall be 
considered a repair, provided the changes 
are within the stress limits of the original 
code of construction. 

j) When driving expansion stay heads, the 
opposite end shall be bucked or braced 
to prevent damaging the threads. Bracing 
can be done several ways, such as using a 
pneumatic holder-on or heavy steel buck- 
ing bar. The stay head is to be driven in 
such a manner as to expand radially the 
stay body and threads into the sheet prior 
to forming the head. Merely driving over 
the head is not acceptable. 

k) Telltale holes shall be reopened after driv- 
ing. 



11 to 1 2, or the reverse, shall be considered 
a repair. 



d) A patch bolt applied in place of a rivet shall A09 
be considered an alteration. 

S1.2.9 FLUES, ARCH TUBES, 

CIRCULATORS, THERMIC 
SIPHONS 



S1 .2.9.1 FLUE AND TUBE RE-ENDING 

a) Each boiler tube or flue that is repaired by 
welding is limited to not more than three 
circumferential welded joints. 

b) Re-ending is permitted provided the thick- 
ness of the tube or flue to be re-ended is 
not less than 90% of that required by Table 
S1.2.9. 

c) Re-end pieces shall be new material and 
meet the thickness requirements of Table 
S1.2.9. 



S1.2.7 



THREADED STUDS 



Studs threaded into the boiler or firebox sheets 
shall not be seal welded. 



S1.2.8 PATCH BOLTS 

(SEE FIGURE S1 .2.8) 

a) Patch bolts may be replaced in kind. 

b) Seal welding of bolts is permitted. 

A09 c) Patch bolts shall have either 11 or 1 2 thread 
pitch. Patch bolt threads shall be fit to sup- 
port the structure to which the bolt is ap- 
plied. Changing the patch bolt thread from 



l l a. i 



NATIONAL BDARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



TABLE S1 .2.9 

Maximum allowable working pressures for steel tubes or flues for firetube boilers for different diameters and gages 
of tubes conforming to the requirements of spec. SA-176, SA-192, SA-209, or SA-210* 



Outside 

diameter of 

tube, inches 

D 


Minimum gage, Birmingham Wire Gage (BWG), inches 


13 
t = 0.095 


12 
t= 0.109 


11 
t = 0.120 


10 

t= 0.134 


9 
1 = 0.148 


8 
t = 0.165 


7 
1 = 0.180 


6 
t = 0.203 


5 
t = 0.220 


4 
t = 0.238 


1 


470 


690 


- 


- 


- 


- 


- 


— 


— 


— 


1-1/2 


320 


460 


570 


720 


860 


- 


- 


- 


— 


— 


1-3/4 


270 


400 


490 


620 


740 


890 


- 


— 


— 


— 


2 


240 


350 


430 


540 


650 


780 


900 


— 


— 


— 


2-1/4 


210 


310 


380 


480 


580 


690 


800 


960 


— 


— 


2-1/2 


190 


280 


350 


430 


520 


620 


720 


860 


970 


1080 


3 


160 


230 


290 


360 


430 


520 


600 


720 


810 


900 


3-1/4 


- 


210 


270 


330 


400 


480 


550 


660 


740 


830 


3-1/2 


- 


200 


250 


310 


370 


450 


510 


620 


690 


770 


4 


- 


180 


220 


270 


330 


390 


450 


540 


610 


680 


4-1/2 


- 


160 


190 


240 


290 


350 


400 


480 


540 


600 


5 


- 


- 


180 


220 


260 


310 


360 


430 


490 


540 


5-3/8 


- 


- 


160 


200 


240 


290 


340 


400 


450 


500 


5-1/2 


- 


- 


- 


200 


240 


290 


330 


390 


440 


490 


6 


- 


- 


- 


180 


220 


260 


300 


360 


410 


450 


P = {(t-0.65)/D) x 15550 where P = maximum allowable working pressure, pounds per square inch, 
t = minimum wall thickness, inches, 
D = outside diameter of tubes, inches. 


For pressures below those given in the table, the gage thickness shall be not less than the minimum given in the table. 
' Calcuiated values of pressure have been rounded to the next higher unit ot 10 psi. 



TABLE S1.2.9M 

Maximum allowable working pressures for steel tubes or flues for firetube boilers for different diameters and gages 
of tubes conforming to the requirements of spec. SA-176, SA-192, SA-209, or SA-210* 



Outside 

diameter of 

tube, mm 

D 


Minimum gage, Birmingham Wire Gage (BWG), to mm 


13 
t = 2.4 


12 
t- 2.8 


11 
t = 3.0 


10 
t=3.4 


9 
t = 3.8 


8 
t = 4.2 


7 
t = 4.6 


6 
t = 5.2 


5 
t = 5.6 


4 
1 = 6.0 


25 


3250 


4950 


- 


- 


- 


- 


- 


— 


— 


— 


40 


2150 


3250 


3850 


4950 


6100 


- 


- 


— 


— 


— 


45 


1850 


2800 


3300 


4300 


5250 


6250 


— 


— 


— 


— 


50 


1650 


2450 


2850 


3700 


4550 


5350 


6200 


— 


— 


— 


60 


1450 


2200 


2550 


3300 


4050 


4800 


5550 


6700 


— 


— 


65 


1300 


1950 


2300 


2950 


3600 


4300 


4950 


5950 


6650 


7300 


75 


1100 


1650 


1950 


2500 


3050 


3600 


4200 


5000 


5600 


6150 


85 


- 


1500 


1750 


2300 


2800 


3300 


3850 


4600 


5100 


5650 


90 


- 


1400 


1650 


2150 


2600 


3100 


3550 


4300 


4750 


5250 


100 


- 


1250 


1450 


1850 


2300 


2700 


3100 


3750 


4150 


5600 


115 


- 


1100 


1300 


1650 


2050 


2400 


2800 


3300 


3750 


4100 


125 


- 


- 


1150 


1500 


1850 


2200 


2500 


3000 


3350 


3700 


135 


- 


- 


1100 


1400 


1700 


2000 


2350 


2800 


3100 


3400 


140 


- 


- 


- 


1350 


1650 


2000 


2300 


2750 


3050 


3350 


150 


- 


- 


~ 


1250 


1550 


1800 


2100 


2500 


2800 


3100 


P = {(t-1 .65)/D) x 1 07000 where P = maximum allowable working pressure, kilopascals (kPa), 
t= minimum wall thickness, mm, 
D = outside diameter of tubes, mm. 


For pressures below those given in the table, the gage thickness shall be not less than the minimum given in the table. 
* Calculated values of pressure have been rounded to the next higher unit of 50 kPa, 



1 1 B.Z 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



S1 .2.9.2 ARCH TUBES 

a) Arch tubes that are damaged or reduced to 
less than minimum required wall thickness 
shall be replaced in entirety by new one- 
piece arch tubes. Welded repairs or partial 
replacement is not permitted. Damage in- 
cludes defects such as bulging, burns, and 
cracks. 

b) When arch tubes are installed by rolling, the 
tube end shall project through the firebox 
sheet not less than 1/4 in. (6 mm) nor more 
than 3/4 in. (19 mm) before flaring. At a 
minimum the tube shall be expanded and 
flared at least 1/8 in. (3 mm) greater than 
the diameter of the tube hole. Additionally, 
the tube may be beaded and/or seal welded 
provided the throat of the seal weld is not 
more than 3/8 in. (1 mm), and the tube is 
finished rolled after welding. 

c) An arch tube installed by welding shall 
be considered a welded nozzle. Some ac- 
ceptable weld joints are shown in Figure 
S1.2.9.2-a Ref. ASME Section I, Part PW 
16.1. 



FIGURE S1.2.9.2-b 

Example of Thermal Fire Crack 



ARCH TUBES 





Akv-h tube end 
rolled ajjd flar2d 



mc'A T(m?. tm 

ROLLED &m BgftDSU 



Mien tgbe mn 

SIM, WELDED 



d) A change in tube attachment from rolled 
to welded or welded to rolled shall be 
considered an alteration. 



S1 .2.9.3 TUBE WALL THICKNESS FOR 
ARCH TUBES 

The minimum wall thickness of replace- 
ment arch tubes shall be as shown in Table 
S1 .2.9.3. 



TABLE S1. 2.9.3 



Size 


WaN Thickness 


Up to 3 in. (75 mm)OD 


8 Birmingham wire 
gage (BWC) 


More than 3 in. (75 mm) 
ODto4 in. (100 mm) OD 


7 Birmingham wire 
gage (BWC) 



SI. 2.9.4 THERMIC SIPHONS 

a) For repairs to siphon knuckles see Repair 
of Firebox and Tubesheet Knuckles, and 
Figures S1 .2.1 1 .5-a and S1 .2.1 1 .5-b. 

b) All weld repairs to the unstayed sections of 
the siphon neck and body shall be radio- 
graphically examined. 



SI. 2.9.5 CIRCULATORS 

a) All butt welds on circulators shall be radio- 
graphically examined. 

b) Welds applied to the circulator/firebox 
sheet joint shall be in accordance with 
the weld requirements for arch tubes. (See 
Figure S1.2.9.2-a). 



S1 .2.9.6 RE-ROLLING OF FLUE-TUBES 
AFTER SEAL WELDING 



A08 



All flues and tubes that are installed by rolling 
and seal welding shall be re-rolled after seal 
welding is complete. 



1 1 9 



NATIDNAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



A09S1 .2.9.7 FERRULES 

A09 a) Ferrous or non-ferrous ferrules may be used 
on either or both ends of flues and arch 
tubes. 

A09 b) The application of ferrules where nonewere 
used before, shall be considered a repair. 

A09 c) The application without ferrules, where 
they were used before shall be considered 
a repair. 



S1.2.10 REPAIRS AND ALTERATIONS 

TO BOILER BARREL UNSTAYED 
AREAS 

a) Defects such as cracks and wastage may be 
repaired by weld buildup, a welded flush 
patch or a riveted patch. Installation of a 
riveted patch shall be considered an altera- 
tion. Prior to repairing cracks, the plate shall 
be examined for defects. Affected sections 
shall be repaired. 



FIGURE S1.2.9.4-a 

Locomotive Firebox Thermic Siphon Installation 






staybolt body 



thermic siphon 



FIGURE S1.2.9.4-b 
Thermic Siphon Repair 



full penetration welds 



section on w-w 




length to suit 



flush patch on staybolt siphon body 




siphon neck repair 



full penetration weld 
radiographically 
examined after weldine 



1 2D 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



b) Weld buildup shall not be used if the af- 
fected section of plate has wasted below 
60% of the minimum required thickness. 

c) If the cracked section of plate is retained 
and is to be repaired by installation of a 
riveted patch, the crack may be stopped by 
drilling stop holes at each end or removed 
by a method such as grinding, cutting, or 
machining. Results of stop drilling or crack 
removal shall be verified by NDE. 

d) Welded repairs at or near riveted seams 
requiring preheating or postweld heat 
treatment shall be carefully made in order 
to prevent loosening in the riveted seams, 
especially when localized heating is used. 
Where necessary to control expansion or 
to gain access for welding, rivets at the 
defective section and to each side of it may 
be removed. Reuse of rivets and staybolts 
is prohibited. 

e) All welded repairs to boiler barrel unstayed 
areas shall be radiographically examined 
in accordance with ASME Code, Section I, 
when the size of the repaired area is greater 
than the maximum size of an unreinforced 



A08 



FIGURE S1 .2.11.1 




Example of Thermal Fire 


Crack 


FIRESIDE 




WATER SIDE 





opening as calculated in accordance with 
the latest edition of ASME Code, Section I. 

Riveted patches may be any shape or size 
provided the lowest patch efficiency is 
equal to or greater than the lowest equiva- 
lent seam efficiency of the boiler course 
to which it is applied. Ref: ASME Code, 
Section I. 



FIGURE S1.2. 11.2 

Typical Firebox Patches 

This figure illustrates what would be considered a 
saw-tooth patch. Its advantage is that a maximum 
amount of welding is obtained for securing a given 
patch and by zig-zagging the weld, the weld is 
supported by three rows of staybolts instead of two. 
Its disadvantage is its irregular shape which causes 
greater difficulty in fitting and applying. 




Saw-Tooth Patch 



^7— r~~ 


-- — — - — J 


-4 






1 












l_ 












-< 


► ■ 




] 




























■■*. 
















* ( 




I - -i 


*■—- < 


>■' — < 


►-■ 


-i 


►— 


































































V 


V 


El 


D 




















» 
















{ 










4 


























































I 


















? tj 































Rectangular Shaped Patch 




Diamond Shaped Patch 



1 2 1 



NATIONAL BDARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



The factor of safety of all riveted patches 
shall not be less than four for locomotives 
operating under Federal Railroad Adminis- 
tration regulations. 



S1.2.11 REPAIRS AND ALTERATIONS TO 
BOILER BARREL STAYED AREA 



S1 .2.1 1 .1 FIREBOX SHEET REPAIR 

a) Cracks in all stayed firebox sheets may be 
repaired by welding or the installation of a 
flush patch. 

b) If the crack extends into a staybolt or rivet 
hole, the staybolt or rivet shall be removed 
prior to making the repair. 

A07 c) Fire cracks or thermal fatigue cracks in 
riveted seams located in the firebox that 
run from the edge of the plate into the rivet 
holes may be left in place provided they 
do not leak and there is no indication that 

A08 the seam or rivets are loose. (See Figure 
SI .2. 11.1). 



FIGURE S1. 2.1 1.3 

Stayed Firebox Sheet Grooved or Wasted 

at Mudring 

Firebox Sheets 



r\j F 




r irst Staybolt Row 
/ 



' i|i |' |i|'|i 1 1 1 1 1 1 1 1 1 • f I i 



Sheet Wasted Below 
Mudring Waterside 




// / / / 




T 

Mudring Rivet Mudring/ 




S1.2.11.2 FIREBOX PATCHES 

a) fetches may be any shape provided they are 
adequately supported by staybolts, rivets, 
tubes, or other forms of construction, fetches 
on stayed surfaces should be designed so weld 
seams pass between staybolt rows. (See Figure 
SI .2. 11.2). 

b) fetches are to be flush type, using full penetra- 
tion welds. If the load on the patch is carried by 
other forms of construction, such as staybolts, 
rivets, or tubes, radiographic examination and A08 
postweld heat treatment of the welds are not 
required. 

c) If the patch includes an existing riveted seam, 
the patch shall be riveted at that seam. Chang- 
ing a riveted seam to a welded seam is con- 
sidered an alteration. 

d) All rectangular or angled patches shall have ad- 
equate radius at all corners. Minimum radius to 
be not less than three times plate thickness. 



FIGURE SI .2.1 1.4 
Mudring Repairs 



mudring 




remove fire box sheets for access 




full penetration weld 



1 22 



NATIDNAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



e) Patches shall fit flush on the waterside of 
the sheet. Misalignment shall not exceed 
one-quarter plate thickness on edge align- 
ment with the sheet water side. 

f) Staybolts and rivets should be installed after 
welding of patch is completed. Reuse of 
staybolts and rivets is prohibited. 

g) Weld seams parallel to a knuckle shall be 
located no closer to the knuckle than the 
point of tangency of the knuckle unless 
the weld is radiographically examined. 
Weld seams not located in the knuckle are 
preferred. (See Figure S1 .2.1 1 .5-b). 

h) Patches shall be made from material that 
is at least equal in quality and thickness to 
the original material. 



S1 .2.1 1.3 REPAIR OF STAYED FIREBOX 

SHEETS GROOVED OR WASTED 

ATTHEMUDRING 

a) Grooved or wasted firebox sheets having 
greater than 60% of the minimum required 
thickness remaining may be repaired by 
weld buildup provided the wastage does 
not extend below the waterside surface of 
the mudring and the strength of the struc- 
ture will not be impaired. If extensive weld- 
ing is required, the affected area shall be 
removed and replaced with a flush patch. 

b) If the sheet thickness has been reduced to 
less than 60% of the minimum required 
thickness, the affected section shall be 
removed and replaced with a flush patch. 

c) If wastage and grooving extends below the 



FIGURE S1. 2.1 1.5-a 

Firebox Tubesheet Knuckle Repair 



staybolts 



knuckle 




transverse crack in 
tubesheet knuckle 



parallel crack in 
tubesheet knuckle 



tubesheet 




«-0~;«0-™O^rC>^f O rt 



)OOOOgo 



95° 



knuckle patch welded through tube holes 




1),- top flue 



line of weld is to be as neatly 
horizontal as conditional will permit II- — flue 

sheet 

knuckle patch welded around tube holes 



FIGURE S1.2.11. 5-b 

Repair of Firebox and Tubesheet Knuckles 



see layout 
method in 
Figure 
S1.2.11.5-b1 




point of tangency 
of knuckle 




welds located no closer to 
knuckle than point of tangency 
do not require radiographic 
examination 



1 23 



NATIDNAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



FIGURE S1.2.11.5-b1 

Layout Method of Determining Knuckle Weld Angle 

longitudinal 
axis point 




lustrations are of inside surface of knuckle 



FIGURE S1 .2.1 1.5-c 

Repair of Firebox and Tubesheet Knuckles 

Stayed Patch Applied to Butt-Welded Seam 

staybolt rows point of 
tangency of kn uckle j H 



knuckle 



A '' , i 



tube or 

staybolt rows 









] 



patch length 



^1 



patch length 



weld seams located between staybolt rows 
and above first tube row or staybolt row 



weld seams located between tube rows 
below staybolt rows or tube rows 



Stayed Patch Applied to Riveted Seam 



riveted seam 



I 



(f. 



] 



&# 



patch length 



d 



patch length 



weld seam located above first tube row or staybolt row weld seam located between tube rows or staybolt rows 
Repairs Requiring Radiographic Examination of Weld Seams 

3 n 




1 



weld seam located in knuckle 



4 patch not supported by tubes, 
1 staybolts, or rivets 



1 24 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



FIGURE S1. 2.1 1.5-d 
Firebox Throat Sheet Knuckle 

typical flush patch installed with full 
penetration welds 




if access for welding or riveting is required, 
remove section of exterior or interior sheets 



FIGURE SI. 2.1 1.5-e 
Backhead Knuckle Repairs 



transverse 
weld 



if access 
for welding 
and riveting 
is required, 
remove 
section of 
exterior or 
interior sheets 




original wrapper sheet 



new rivets 




typical flush patch 
patch length 



— stay bo Its 

7 



weld located between staybolt rows 



FIGURE S1.2.11.5-f 

Fire Door Opening Repair 




SEC A-A 



patch installed with full 
penetration welds and 
either patch bolts and rivets 



flush patch installed 
with full penetration 
welds 



A09 



FIGURE S1.2.11.5-g 




Typical Flanged Sheets 








^3-^^==^ V 




Typical Flagged Sheets 




1 . Flanges shall be made smooth and free of ridges, 


valleys 


and grooves. 




2. Flanges may be welded in accordance with this 


section 


and all applicable sections of this code. 





1 25 



NAT1DNAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



d) 



mudring waterside surface and if the plate 
thickness remaining has been reduced to 
less than the minimum required thickness, 
the affected section shall be removed and 
replaced with a flush patch. 

Flush patches shall be arranged to include 
the mudring rivets and at least the first row 
of staybolts above the mudring. 



S1. 2.1 1.4 MUDRING REPAIRS 

(SEE FIGURE SI .2.1 1.4) 



a) 



b) 



Pitted and wasted sections of mudrings 
may be built up by welding provided the 
strength of the mudring will not be im- 
paired. Where extensive weld buildup is 
employed, the Inspector may require an 
appropriate method of NDE for the repair. 

Cracked or broken mudrings may be re- 
paired by welding or installation of flush 
patches using full penetration welds. 
Patches shall be made from material that 
is at least equal in quality and thickness to 
the original material. Patches shall fit flush 
on waterside surfaces. Where necessary, 



FIGURE S1 .2.1 1.6 
Tubesheet Repairs 





typical tubesheet flush patches 




tubesheet welded around tube holes 




tubesheet welded through ligaments and tube holes 



firebox sheets on both sides of the defect 
may be removed to provide access for in- 
spection and welding. 



S1 .2.1 1 .5 REPAIR OF FIREBOX AND 

TUBESHEET KNUCKLES 



a) 



b) 



d) 



Welds within the points of tangency of a 
knuckle are permitted. Welds with angles 
of less than 45 degrees to the longitudinal 
axis of the knuckle shall be radiographically 
examined. (See Figures S1 .2.1 1 .5-a through 
S1.2.11 .5-g). 

Any patch not supported by means other 
than the weld, such as rivets, staybolts, 
tubes, or other forms of construction, shall 
have all weld seams radiographically ex- 
amined. 

Patches shall be formed to proper shape 
and curvature. 

Wasted sections of knuckles that have 
not wasted below 60% of the minimum 
required thickness may be repaired by 
weld buildup provided the strength of the 
structure will not be impaired. Where weld 
buildup is employed, the Inspector may 
require an appropriate method of NDE for 
the repair. 

Wasted sections of knuckles that have 
wasted below 60% of the minimum re- 
quired thickness shall be replaced. 



FIGURE S1.2.12.1 

caulking tool 






« 




V////////A, 



caulked edge of plate 



i za 



NATIONAL BOARD INSPECTION CDDE • PART 3 



REPAIRS AND ALTERATIONS 



f) Flanges shall be made so as to avoid stress 
intensifiers such as abrupt ridges and 
grooves. 



SI .2.1 1.6 TUBESHEET REPAIRS 

(SEE FIGURE S1 .2.1 1.6) 

a) Cracked tubesheet ligaments may be re- 
paired by welding using full penetration 
welds. 

b) Damaged tubesheet holes may be repaired 
by welding. 

c) Sections of tubesheets damaged or wasted 
to less than 60% minimum required thick- 
ness shall be repaired by installing a flush 
patch using full penetration welds. 

d) Sections of tubesheets that have not wasted 
below 60% minimum required thickness 
may be repaired by weld buildup provided 
the strength of the structure will not be im- 
paired. Where weld buildup is employed, 
the Inspector may require an appropriate 
method of NDE for the repair. 



SI .2.1 2 SEAMS AND JOINTS 



S1.2.12.2 THREADED OPENINGS IN 
VESSEL WALLS, BUSHINGS, 

AND WELDED NOZZLES 
(WASHOUT PLUG HOLES AND 
OTHER CONNECTIONS) 

a) Threaded openings in vessel walls and 
welded nozzles with damaged threads 
that cannot be repaired by retapping or 
reth reading should be repaired by welding 
a nozzle in the sheet. The nozzle shall be of 
such a size as to not interfere with proper 
washout and inspection. 

b) Threaded bushings and nozzles found to be 
defective shall be replaced. Seal welding is 
not permitted. 

c) New threaded bushings equipped with 
shoulders may be seal welded at the shoul- 
der. 

d) New threaded bushings without shoulders 
that are seal welded after installation shall 
have the threads removed from the weld 
zone of the bushing prior to welding. 

e) Threaded holes with damaged threads may 
be repaired by weld buildup and re-tapping. 
The threads shall be removed prior to weld- 
ing. 



S1 .2.1 2.1 CAULKING RIVETED SEAMS 
AND RIVET HEADS 
(SEE FIGURE S1.2.12.1) 

a) Caulking refers to the sealing of plate seams 
and rivet heads by driving the edge of one 
surface onto the other by use of an impact 
tool. 

b) Riveted seams and rivet heads may be 
caulked in accordance with ASME Code 
Section I, 1971. 14 



FIGURE S1.2.13 

Straight Run Globe Valve Not Permitted 



14 This Code is available from the National Board. 




1 27 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



S1 .2.1 3 FITTINGS AND GAGES 



S1.2.13.1 WATER GAGE CONNECTION 

a) Water gage glasses shall be applied so that 
the lowest water reading in the water gage 
glass of a horizontal firetube boiler on level 
track shall be at least 3 in. (75 mm) above 
the highest point of the tubes, flues, or 
crownsheet. 



The upper edge of the water connection to a 
water gage glass and the boi ler shall not be 
above the lowest visible water level in the 
water gage glass. There shall be no pockets, 
traps, sags, or siphons in the connection. 



b) The bottom mounting for water gage glass 
(and for water column if used) must not 
extend less than 1-1/2 in. (38 mm) inside 
the boiler and beyond any obstacle im- 
mediately above it. The passage must be 
straight and approximately horizontal. Con- 
nections must be applied without pockets, 
traps, sags, or siphons. Tubular water gage 
glasses must be equipped with a protection 
shield. 

c) Locomotive water gage glasses shall be 
provided with one top and one bottom 
shutoff cock and a means to illuminate 
each glass. Each top and bottom shutoff 
cock or valve shall be of such through flow 
construction as to prevent stoppage by 
deposits of sediments. Straight run globe 
valve of the ordinary type shall not be used 
on such connections. (See Figure S1 .2.13). 
The water gage glass connection and pipe 
connection shall be fitted with a drain cock 
or valve having an unrestricted opening of 
not less than 3/8 in. (10 mm) in diameter 
to facilitate cleaning. 

d) The top and bottom water gage glass fittings 
are to be aligned, supported, and secured 
so as to maintain the alignment of the water 
gage glass. 

e) The lower edge of the steam connection 
to a water column or water gage glass in 
the boiler shall not be below the highest 
visible water level in the water gage glass. 
There shall be no pockets, traps, sags, or 
siphons in the piping that will permit the 
accumulation of sediments. 



1 28 



NATIDNAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



1 2S.1 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



SUPPLEMENT 2 

HISTORICAL BOILERS 



S2.1 SCOPE 

A07 a) This supplement is provided as a guide to 
repair and alteration of historical steam 
boilers of riveted and/or welded construc- 
tion not falling under the scope of Supple- 
ment 1. These historical steam boilers 
would include: steam tractors, traction en- 
gines, hobby steam boilers, portable steam 
boilers, and other such boilers that are 

A07 being preserved, restored and maintained 
for demonstration, viewing, or educational 
purposes. 

A07 Note: This supplement is not to be used 
for steam locomotive boilers falling under 
the requirements of the Federal Railroad 
Administration (FRA). FRA rules for steam 
locomotive boilers are published in 49 CFR 
230. Specific rules and special require- 
ments for inspection, repairs, alterations, 
and storage of steam locomotive boilers 
are identified in Supplement 1 Parts 2 and 
3oftheNBIC. 

A07 b) The rules specified in this supplement shall 
be used in conjunction with the applicable 
rules in this Code. References specified or 
contained in this Supplement may provide 
additional information to assist the user 
when applying the requirements of this 
supplement. 



S2.2 INTRODUCTION 

a) The following repair and alteration rules 
are minimum requirements for safe and 
satisfactory operation of historical boilers. 
Users of this supplement are cautioned that 
where complete details are not provided, 
the user is advised to seek technical guid- 
ance to provide good sound engineering 
evaluations and practices. 

b) Where adopted by a Jurisdiction, these 
requirements are mandatory. Where a Ju- 



risdiction establishes different requirements 
for historical boilers or where a conflict 
exists, the rules of the Jurisdiction prevail. 



S2.3 



RESPONSIBILITIES 



The owner, user and/or operator are responsible 
for ensuring that the boiler meets all the re- 
quirements of the Jurisdiction where the boiler 
is operated, including inspections, repairs, 
licensing, operating certificates, permits, and 
operator training. 

Note: It should be recognized that safety of 
these boilers is dependent upon the knowledge 
and training of the operator in proper use, re- 
pair, maintenance, and safe operation of each 
specific boiler proposed to be operated. (See 
Part 2, Supplement 2.) 



S2.4 



REPAIRS AND ALTERATIONS 



Repairs and alterations to boilers of historical 
nature should be performed with consideration 
towards preserving the authenticity of original 
design, while at the same time ensuring that the 
boiler is safe to operate at the pressure allowed 
by Part 2, Supplement 2. 



S2.5 



CONSTRUCTION STANDARDS 



A07 



Repairs and alterations shall conform to the re- 
quirements of the original construction standard 
insofar as possible. If the original construction 
standard is unknown or unavailable, the boiler 
shall be considered a boiler of locomotive de- 
sign and subject to the construction standard 
most applicable. The construction standard 
selected for the repair or alteration must meet 
the approval of the Jurisdiction. 



1 2B.2 



NATIONAL BDARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



FIGURE S2.13.9.4 
Riveted Boiler Shell fetch 



diagonal riveted patch 

'o s 



circular riveted patch 





typical riveted patch installation 

patch 




S2.13.10.2 WELDED REPAIR OF CRACKS IN A07 
STAYED AREAS 

Requirements specified in S2. 13.9.2 shall ap- A07 
ply with the following additional requirements 
identified below: 

a) If the crack extends into a staybolt hole, the A07 
staybolt shall be removed prior to making 

the repair. 

b) In riveted joints, tack bolts should be placed A07 
in alternating holes to hold the plate laps 
firmly. 

c) Rivets holes should be reamed after weld- A07 
ing. 

d) Welding shall not cover rivet or staybolt 
heads. 



A07 S2.13.10 REPAIRS AND ALTERATIONS TO 
STAYED AREAS 



S2.13.10.3 WELDED FLUSH PATCHES IN 

STAYED AREAS 



A07 



A07 S2.13.10.1 WELD BUILDUP OF WASTAGE 
AND GROOVING IN STAYED 
AREAS 



The requirements identified in S2. 13.9.3 shall A07 
apply with the additional requirements speci- 
fied below: 



A07 a) Requirements specified in S2. 13.9.1 shall 
be followed. Welding shall not cover rivet 
or staybolt heads. 

A07 b) Prior to welding the rivets and or staybolts 
in the wasted areas should be removed. 

A07 c) Threaded staybolt holes shall be retapped 
after welding. 

A07 d) Welding shall not cover rivet or staybolt 
heads. 

A07e) See Figure S2.1 3. 10.3-a. 



a) Patches may be any shape provided they A07 
are adequately supported by staybolts, 
rivets, tubes, or other forms of construc- 
tion. Patches on stayed surfaces should 

be designed so weld seams pass between 
staybolt rows. (See Figure S2.13.10.3). 

b) Patches are to be flush type, using full pen- A07 
etration welds. If the load on the patch is 
carried by other forms of construction, such 

as staybolts, rivets, or tubes, radiographic 
examination of the welds is not required. 

c) Staybolts and rivets should be installed after A07 
welding of patch is completed. Reuse of 
staybolts and rivets is prohibited. 

d) Weld seams parallel to a knuckle shall be A07 
located no closer to the knuckle than 



1 39 



NATIDNAL BDARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



A07 



FIGURE S2.13.10.3 

Stayed Area Flush Patch 



?v 



. I •'' 



(2 , 




: '~' ■' 



I ■'< 



I '> 1 




the point of tangency of the knuckle 
unless the weld is radiographically 
examined. Weld seams not located in 
the knuckle are preferred. (See Figure 
S2.13.10.3-a). 



A07 S2.13.10.4 REPAIR OF STAYED FIREBOX 

SHEETS GROOVED OR WASTED 
ATTHEMUDRING 

A07 a) Mudrings of the Ogee style (knuckle) shall 
be repaired in accordance with S2.13.11. 

A07 b) For Mudrings of the locomotive style (see 
Figure S2.13.10.4), grooved or wasted 
firebox sheets having greater than 60% of 
the minimum required thickness (see Figure 
S2. 13.9.1) remaining may be repaired by 
weld buildup provided the wastage does 
not extend below the waterside surface of 
the mudring and the strength of the struc- 
ture will not be impaired. If extensive weld- 
ing is required, the affected area shall be 
removed and replaced with a flush patch. 

A07 c) If the sheet thickness has been reduced to 
less than 60% of the minimum required 
thickness, the affected section shall be 
removed and replaced with a flush patch. 

A07 d) If wastage and grooving extends below the 
mudring waterside surface and if the plate 
thickness remaining has been reduced to 



FIGURE S2.13.l0.3-a 
Knuckle Point of Tangency 



point of 
tangency of 
knuckle 




7 



kunckle 
radius 



A07 



less than the minimum required thickness, 
the affected section shall be removed and 
replaced with a flush patch. (See Figure 
S2.13.10.4). 

Flush patches shall be arranged to include A07 
the mudring rivets and at least the first row 
of staybolts above the mudring. (See Figure 
S2.13.10.4-a). 

For mudrings of the locomotive style, pitted A07 
and wasted sections of mudrings may be 
built up by welding provided the strength 
of the mudring will not be impaired. Where 
extensive weld buildup is employed, the In- 
spector may require an appropriate method 
of NDE for the repair. 



1 4D 



NATIONAL BOARD INSPECTION CODE * PART 3 



REPAIRS AND ALTERATIONS 



c) Barcol hardness tester; 

d) small pick or pen knife; 

e) small quantity of acetone and cotton 
swabs; 

f) camera with flash capability; and 

g) liquid penetrant testing kit. 



S4.4 



LIMITATIONS 



All field work shall be limited to secondary 
bonding. 



S4.5 REPAIR LIMITATIONS FOR 

FILAMENT WOUND VESSELS 

When the MAWP is greater than 200 psig (1 .38 
MPa), field repair of filament wound ASME 
Code Section X, Class I vessels shall be lim- 
ited to corrosion barrier or liner repairs only, 
provided there is access to the vessel interior. 
No structural repairs, re-rating, or alterations 
are allowed for filament wound ASME Code 
Section X, Class 1 vessels that have an MAWP 
greater than 200 psig (1 .38 MPa). 



S4.6 VESSELS FABRICATED USING 

ELEVATED TEMPERATURE 
CURED RESIN SYSTEMS 

Repair of vessels fabricated using elevated tem- 
perature cured resin systems shall be limited to 
the corrosion barrier or liners only, providing 
there is adequate access to the vessel surface 
that requires the repair. No structural repairs, 
re-rating or alterations are permitted with the 
following exceptions: 

a) Repair of vessels fabricated using elevated 
temperature cured material is permitted 
only if the following provisions are met: 

A09 1) Calculations must be submitted by an 
Engineer meeting the ASME Section X 
criteria for an Engineer certifying ASME 



b) 



Section X or RTP-1 compliance of the 
appropriate calculations contained in 
the Fabricator's Design Report. 

NOTE:The Engineer qualification criteria of 
the Jurisdiction, where the pressure ves- 
sel is installed should be verified before 
selecting the certifying engineer. 

2) The original fabricator must provide its 
approval showing that the damage does 
not compromise the pressure rating of 
the vessel and that the safety factor re- 
quired by the ASME Code or the original 
code of construction is maintained. 

Repairs that results in a revision to the pres- 
sure rating of a vessel covered as a part of 
this section is permitted providing the new 
rating is less than the original rating and 
as long as the safety factor required by the 
ASME Code or the safety factor used as 
a design basis from the original code of 
construction is met in its entirety and all 
the requirements under S4.17, Additional 
Requirements for Alterations, are met. 



S4.7 



CODE OF CONSTRUCTION 



a) When the standard governing the original 
construction is the ASME Code Section X or 
ASME RTP-1, repairs and alterations shall 
conform, insofar as possible, to the section 
and edition of ASME Code Section X or 
ASME RTP-1 most applicable to the work 
planned. 

b) When the standard governing the original 
construction is not the ASME Code Section 
X or ASME RTP-1, repairs and alterations 
shall conform to the original code of con- 
struction or standard. Where this is not pos- 
sible, it is permissible to use other codes, 
standards, or specifications, including the 
ASME Code (Section X or RTP-1 ), provided 
the "RP" designated "R" certificate holder 
(hereafter called the certificate holder) has 
the concurrence of the Inspector and the 
Jurisdiction where the pressure-retaining 
item is installed. 



i e l 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



S4.8 



MATERIALS 



The materials used in making repairs or altera- 
tions shall conform to the requirements of the 
original code of construction. All resins and 
reinforcements must be properly stored and 
prevented from being contaminated by water, 
soil, or other impurities. The certificate holder 
is responsible for verifying identification of 
existing materials from original data, draw- 
ings, or units records, and identification of the 
materials to be installed. Consideration shall be 
given to the condition of the existing laminate, 
especially in the secondary bond preparation 
area. 



shall be manufactured by an organization 
certified as required by the original code of 
construction. The item shall be inspected 
and stamped as required by the original 
code of construction. Certification to the 
original code of construction as required 
by the original code of construction or 
equivalent shall be supplied with the item. 
When this is not possible or practicable, the 
organization fabricating the part may have a 
National Board Certificate of Authorization. 
Replacement parts shall be documented on 
Form R-3 and the "R" symbol stamp applied 
as described in 5.7. 



S4.9 



REPLACEMENT PARTS 



a) Replacement parts that will be subject to in- 
ternal or external pressure including liquid 
head that are preassembled with or without 
secondary bonds shall have the fabrication 
performed in accordance with the original 
code of construction. The fabricator shall 
certify that the material and fabrication 
are in accordance with the original code 
of construction. This certification shall be 
supplied in the form of bills of material and 
drawings with statements of certification. 
Examples include shell and head sections, 
or flanged nozzles. 

b) When ASME is the original code of con- 
struction, replacement parts subject to in- 
ternal or external pressure that require shop 
inspection by an Authorized Inspector or by 
a Certified Individual as defined by ASME 
RTP shall be fabricated by an organization 
having an appropriate ASME Certificate of 
Authorization. The item shall be inspected 
and stamped or marked as required by the 
original code of construction. A completed 
ASME Fabricator's Partial Data Report shall 
be supplied by the fabricator. 

c) When the original code of construction 
is other than ASME, replacement parts 
subject to internal or external pressure 



S4.10 SECONDARY BONDING 

Secondary bonding shall be performed in 
accordance with the requirements of the origi- 
nal code of construction used for the pressure- 
retaining item. 



S4.10.1 SECONDARY BONDING 

PROCEDURE SPECIFICATIONS 

Secondary bonding shall be performed in 
accordance with the lamination procedure 
qualified in accordance with the original code 
of construction. 



S4.10.2 PERFORMANCE 

QUALIFICATIONS 

Secondary bonders shall be qualified for the 
lamination process that is used. Such qualifica- 
tions shall be in accordance with the require- 
ments of the original code of construction. 



S4.10.3 RECORDS 

The certificate holder shall maintain a record 
of the results obtained in secondary bonder 
procedure qualifications. These records shall 
be certified by the certificate holder and shall 
be available to the Inspector. 



1 S2 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



S4.16 



During the vacuum test, the vacuum 
source may be left connected to the 
vessel to compensate for leakage at 
fittings. All vessels acoustic emission 
tested, as required by the original code 
of construction, shall be retested during 
the vacuum test concentrating on the 
repaired or altered part of the vessel. 



ADDITIONAL REQUIREMENTS 
FOR REPAIRS 



S4.16.1 SCOPE 

This section provides additional requirements 
for repairs to pressure-retaining items and shall 
be used in conjunction with S4.1 thru S4.14 
and S4.18. 



S4.16.2 DRAWINGS 

Drawings shall be prepared or modified to 
describe the repair. Drawings shall include 
sufficient information to satisfactorily perform 
the repair. 



S4.16.3 



REPAIR PLAN 



When repairs other than those defined in 
S4.16.4 are being made to ASME Section X 
or RTP-1 stamped equipment, the user shall 
prepare or cause to have prepared a detailed 
plan covering the scope of the repair. 

a) Engineer Review and Certification 

The repair plan shall be reviewed and 

A09 certified by an engineer meeting the ASME 
Section X or RTP-1 criteria for an engineer 
certifying ASME Section X or RTP-1 com- 
pliance of the appropriate calculations 
contained in the Fabricator's Design Report. 
The review and certification shall be such 

A09 to ensure that the work involved in the re- 
pair is compatible with the User's Design 
Specification or User's Basic Requirements 
Specification and the Manufacturer's De- 



sign Report. The certification shall also 
include any drawings and calculations 
prepared as part of the repair plan. 

NOTE: The engineer qualification criteria of 
the jurisdiction, where the pressure vessel 
is installed should be verified before select- 
ing the certifying engineer. The certification 
shall also include any drawings and calcu- 
lations prepared as part of the repair plan. 

b) Authorized Acceptance 

Following review and certification, the 
repair plan shall be submitted to the Inspec- 
tor for his review and acceptance. Repairs 
to pressure-retaining items shall not be 
initiated without the authorization of the 
Inspector. Subject to acceptance of the 
Jurisdiction, the Inspector may give prior 
approval for routine repairs, provided the 
Inspector assures that the certificate holder 
has acceptable procedures covering the 
repairs. 



S4.16.4 ROUTINE REPAIRS 

Prior to performing routine repairs, the cer- 
tificate holder should determine that routine 
repairs are acceptable to the Jurisdiction where 
the work is to be performed. 

a) Acceptable routine repairs are listed be- 
low: 

1) The addition or repair of non-load 
bearing attachments to pressure-re- 
taining items where post curing is not 
required. 

2) Replacement and repair of damaged 
corrosion liner areas in shells and heads 
shall not exceed 1 00 sq. in. (65 sq. cm) 
and not exceed the original corrosion 
liner thickness. 

b) Routine repairs may be performed under the 
certificate holder's quality system program; 
however, the requirement for in-process 
involvement of the Inspector and stamping 
are waived. (See Section 5 of this part). 



1 69 



NATIDNAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



c) The process of controlling and implement- 
ing routine repairs shall be documented 
in the certificate holder's quality system 
program. 

d) Routine repairs shall be documented on 
a Form R-1 with a statement on line 10, 
Remarks: "Routine Repair". 



S4.16.5 REPAIR METHODS 

The repair methods shall be acceptable to the 
inspector. Some methods of repair are con- 
tained in S4.18. 



S4.17 ADDITIONAL REQUIREMENTS 

FOR ALTERATIONS 



S4.17.1 SCOPE 

This section provides additional requirements 
for alterations to pressure-retaining items, and 
shall be used in conjunction with S4.1 thru 
S4.14andS4.18. 



S4.17.2 DESIGN 

The certificate holder performing alterations 
shall establish controls to ensure that all re- 
quired design information, applicable draw- 
ings, design calculations, specifications and 
instructions are prepared, obtained, controlled, 
and interpreted to provide the basis for an al- 
teration in accordance with the original code of 
construction. When a Fabricator's Data Report 
is required by the original code of construc- 
tion, a copy of the original data report shall be 
obtained for use in the design of the alteration. 
When the original Fabricator's Data Report 
cannot be obtained, agreements on the method 
of establishing design basis for the alteration 
shall be obtained from the Inspector and the 
Jurisdiction. 



S4.17.3 ALTERATION PLAN 

The user shall prepare or cause to have pre- 
pared a detailed plan covering the scope of 
the alteration. 

a) Engineer Review and Certification 

The alteration plan shall be reviewed and 
certified by an engineer meeting the ASME A09 
Section X or RTP-1 criteria for an engineer 
certifying ASME Section X or RTP-1 com- 
pliance of the appropriate calculations 
contained in the Fabricator's Design Report. 
The review and certification shall be such 
as to ensure that the work involved in the 
alteration is compatible with the user's de- 
sign specification and the Fabricator's Data 
Report. 

NOTE: The engineer qualification criteria of A09 
the jurisdiction where the pressure vessel is 
installed should be verified before selecting 
the certifying engineer. 

b) Authorized Acceptance 

Following review and certification, the 
alteration plan shall be submitted to the 
Inspector for his review and acceptance. 
Alterations to pressure-retaining items shall 
not be initiated without the authorization 
of the Inspector. 



S4.17.4 CALCULATIONS 

A set of calculations shall be completed prior 
to the start of any physical work. All design 
work shall be completed by an organization 
experienced in the design portion of the stan- 
dard used for the construction of the item. All 
calculations for ASME Code Section X and RTP- 
1 alterations shall be certified by an engineer 
meeting the ASME Section X criteria for an 
engineer certifying ASME Section X compliance 
of the calculations contained in the Fabricator's 
Design Report. All calculations shall be made 
available for review by the Inspector. 



1 vo 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



NOTE: The engineer qualification criteria of 
the jurisdiction where the pressure vessel is 
installed should be verified before selecting 
the certifying engineer. 

S4.17.5 RE-RATSNG 

a) Re-rating of a pressure-retaining item 
by increasing the maximum allowable 
working pressure (internal or external) or 
temperature, or decreasing the minimum 
temperature shall be done only after the 
following requirements have been met to 
the satisfaction of the Jurisdiction at the 
location of the installation: 

1 ) Revised calculations verifying the new 
service conditions shall be prepared in 
accordance with the certificate holder's 
Quality Control System. Re-rating 
calculations for ASME Code Section X 
and RTP-1 vessels shall be performed 
by a P.E. experienced in the design of 
reinforced plastic pressure vessels. 

2) All re-rating shall be established in 
accordance with the requirements of 
the construction standard to which the 
pressure-retaining item was built. 

3) Current inspection records verify that 
the pressure-retaining item is satisfac- 
tory for the proposed service condi- 
tions. 

4) The pressure-retaining item has been 
pressure tested, as required, for the new 
service conditions. 

b) This code does not provide rules for de- 
rating pressure-retaining items; however, 
when the MAWP and/or allowable tem- 
perature of a pressure-retaining item is re- 
duced, the Jurisdiction wherein the object is 
installed should be contacted to determine 
if specific procedures should be followed. 



S4.17.6 PRESSURE TESTING 

Except as permitted in (g) below, the follow- 
ing requirements apply for pressure testing of 
alterations to pressure-retaining items: 

a) When the alteration activity involves the 
installation of a replacement part and/or 
the alteration will impact the design pres- 
sure, the design temperature, or the design 
rated capacity, a pressure test, as required 
by the original code of construction, shall 
be conducted. An acoustic emission test 
is also required if the original vessel was 
so tested, unless a nozzle whose diameter 
is one tenth the vessel diameter or less is 
being added. 

The certificate holder is responsible for 
all activities related to pressure testing of 
replacement parts. The pressure test may 
be performed at the point of manufacture 
or point of installation. 

b) The pressure test of replacement parts and 
connecting secondary bonds shall be tested 
at 1 .1 times the maximum allowable work- 
ing pressure or the original test pressure, 
whichever is greatest. 

c) During the pressure test, where the test 
pressure will exceed the set pressure of the 
pressure relief device, the device shall be 
prepared as recommended by the device 
manufacturer. 

d) The liquid temperature used for pressure 
testing shall not be less than 40°F (4°C) nor 
more than 1 20°F (49°C) unless the original 
pressure test was conducted at a higher 
temperature. If an acoustic emission exami- 
nation is being conducted, the temperature 
of the test liquid shall not vary by more than 
plus 5°F (-1 5°C) or minus 1 0°F (-23°C). 

e) Hold time for the pressure test shall be a 
minimum of 30 minutes with an acoustic 
emission examination or a minimum of 
four hours without an acoustic emission 
examination. The following procedure shall 



1 71 



NATIONAL BOARD INSPECTION CODE * PART 3 



REPAIRS AND ALTERATIONS 



be used to retest a vessel that has been 
tested under the provisions of Article 6 of 
ASME Section X and has subsequently been 
repaired. 

1 ) Load the vessel as specified in Article 6 
of ASME Section X without monitoring 
for acoustic emission. 

2) Hold the maximum load for at least 30 
minutes. 

3) Condition the vessel by holding at 
reduced load as required by Section V, 
Article 11, T-1 121. 

4) Retest the vessel as required by this 
appendix. 

5) The vessel shall be judged against the 
evaluation criteria for subsequent load- 
ings. 

f) Hold time for the examination by the In- 
spector shall be the time necessary for the 
Inspector to conduct the inspection. 

g) When pressure testing using liquids is not 
practical, other methods shall be used as 
follows: 

1 ) The pressure test may be a pneumatic 
test provided the certificate holder has 
the concurrence of the Inspector, the 
jurisdictional authority where required, 
and the owner. Precautionary require- 
ments of the applicable section of the 
original code of construction shall be 
followed. 

2) For vessels designed for vacuum, a 
vacuum test shall be carried out to as 
close as practical to the design vacuum 
level of the vessel. During the vacuum 
test the vacuum source may be left 
connected to the vessel to compensate 
for leakage at fittings. All vessels origi- 
nally acoustic emission tested shall be 
retested during the vacuum test concen- 
trating on the repaired or altered part 
of the vessel. 



S4.18 REPAIR AND ALTERATION 

METHODS 



S4.18.1 GENERAL REQUIREMENTS 

a) In general, when a defective or damaged 
vessel wall is to be repaired, the total struc- 
tural laminate sequence of laminate con- 
struction removed as part of the repair shall 
be replaced. The replacement laminate 
shall provide structural properties meeting 
or exceeding the requirement of the origi- 
nal construction standard. Moreover, when 
damage includes the corrosion barrier, a 
corrosion barrier of the same type, which 
shall meet or exceed the barrier properties 
of the original construction, shall replace 
the corrosion barrier removed as part of the 
repair. 

b) The repair shall meet the requirements of 
the original construction standard. 



S4.18.2 CLASSIFICATION OF REPAIRS 

a) Vessel repairs shall be classified into the 
following types: 

1 ) Type 1 a — Corrosion barrier repairs 

2) Type 1b — Corrosion barriers with 
precision bores 

3) Type 2 — Corrosion barrier and interior 
structural layer repairs 

4) Type 3 — External structural layer 
repairs 

5) Type 4 — Alterations 

6) Type 5 — Miscellaneous general exter- 
nal repairs or alterations 

7) Type 6 — Thermoplastic repairs 

8) Type 7 — Gel coat repairs 



1 72 



NATIDNAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



b) The "VR" and "NR" stamps shall be applied 
only to "NV" stamped (Class 1, 2, or 3) 
National Board capacity certified pressure 
relief devices that have been disassembled, 
inspected, and repaired as necessary, such 
that the valves' condition and performance 
are equivalent to the standards for new 
valves. 

c) All measuring and test equipment used in 
the repair of pressure relief devices shall be 
calibrated against certified equipment hav- 
ing known valid relationships to nationally 
recognized standards. 

d) Documentation of the repair of "NV"- 
stamped pressure relief devices shall be 
recorded on the National Board Form NVR- 
1 , Report of Repair/ Replacement Activities 
for Nuclear Pressure Relief Devices, in ac- 
cordance with the requirements of 1.8 of 
this part. 

e) When an ASME "NV"-stamped pressure 
relief device requires a duplicate nameplate 
because the original nameplate is illegible 
or missing, it may be applied using the 
procedures of 5.9.5 provided concurrence 

A08 is obtained from the Authorized Nuclear 
Inspector and Jurisdiction. In this case the 
nameplate shall be marked "SEC. Ill" to in- 
dicate the original ASME Code stamping. 



z i i 



NATIONAL BOARD INSPECTION CODE • PART 3 



REPAIRS AND ALTERATIONS 



SUPPLEMENT 10 

REPAIR AND ALTERTIONS OF 
PRESSURE VESSELS IN LIQUE- 
FIED PETROLEUM GAS SERVICE 



S10.1 



SCOPE 



A09 This Supplement provides general and specific 
requirements that apply to the repairs or altera- 
tions to pressure vessels designed for storing 
Liquid Petroleum Gas (LPG) and fabricated in 
accordance with the ASME Boiler and Pressure 
Vessel Code, Section VIII, Division 1, or the 
API-ASME Code for Unfired Pressure Vessels 
for Petroleum Liquid and Gases. When the 
standard governing the original construction 
is not the ASME Boiler and Pressure Vessel 
Code, Section VIII, Division 1 or the API-ASME 
Code for Unfired Pressure Vessels for Petro- 
leum Liquid and Gases, the requirements of 
Paragraph 1 .2 b), Part 3, Section 1 , shall apply. 
In addition to this supplement, the applicable 
paragraphs of Part 3 of the NBIC shall be met. 
Vessels used for anhydrous ammonia service 
shall not be considered for repair or alteration 
in accordance with this Supplement. 



A09S10.2 



GENERAL AND 

ADMINISTRATIVE 

REQUIREMENTS 



b) 



Refer to Section 1 of this Part for all applica- 
ble post construction activities pertaining to 
general and administrative requirements. 

Repairs or alterations shall conform to the 
edition of the ASME Code or standard most 
applicable to the work. 



S10.3 



WELDING 



Refer to Section 2 of this Part for all applicable 
post construction activities pertaining to weld- 
ing requirements. 



S10.4 REQUIREMENTS FOR REPAIRS 

AND ALTERATIONS 

a) Refer to Section 3 of this Partfor all applica- 
ble post construction activities pertaining to 
requirements for repairs and alterations. 

1 ) Excluded is Part 3, Section 3, Paragraph 
3.3.4.8 Repair of Pressure-Retaining 
Items Without Complete Removal of 
Defects. 

b) Radiographic or Ultrasonic Examinations 
are considered to be suitable alternative 
nondestructive examination methods to 
assure complete removal of the defect, 
as described in Paragraph 3.3.4.1 of this 
Part. 



S10.5 



EXAMINATION AND TESTING 



Refer to Section 4 of this Partfor all applicable 
post construction activities pertaining to exami- 
nation and testing. 

S10.6 CERTIFICATION/DOCUMENTA- 

TION AND STAMPING 

a) Section 5 of this Part is applicable for all 
post construction activities pertaining to 
certification/documentation and stamp- 
ing. 

b) The "R" certificate holder shall assure all 
repairs or alterations involving a change to 
the following are recorded on the proper 
NBIC form and marked on the NBIC name- 
plate or stamping without changing the 
required format of the NBIC markings. 

1) Service for which the container is 
designed (for example, underground, 
aboveground, or both) 

2) Dip tube length. 

3) Maximum filling limit with liquid tem- 
perature reference. 



2 1 2 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



510.7 INSPECTION 

Refer to Supplement 7 of Part 2 Inspection, 
for all applicable post construction activities 
pertaining to inspection. 

510.8 COATINGS 

When coatings are reapplied, the user should 
verify the coating is compatible with any coat- 
ing that remains intact and is suited for the 
intended service application. 



2 1 2.1 



NATIONAL BDARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



2 1 2.2 




Part 3, Section S 

Repairs and Alterations — 

Glossary of Terms 



223 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 

PART 3, SECTION 9 
REPAIRS AND ALTERATIONS — GLOSSARY OF TERMS 



9.1 



DEFINITIONS 



For the purpose of applying the rules of the 
NBIC, the following terms and definitions shall 
be used herein as applicable to each Part: 

Additional terms and definitions specific to 
DOT Transport Tanks are defined in Part 2, 
Supplement 6. 

A07 Accumulator — A vessel in which the test 
medium is stored or accumulated prior to its 
use for testing. 

Alteration — A change in the item described on 
the original Manufacturer's Data Report which 
affects the pressure containing capability of the 
pressure-retaining item. (See sub-section 3.4.3, 
A09 EXAMPLES OF ALTERATION)Nonphysical 
changes such as an increase in the maximum al- 
lowable working pressure (internal or external), 
increase in design temperature, or a reduction 
in minimum temperature of a pressure-retaining 
item shall be considered an alteration. 

ANS! — The American National Standards 
Institute 

ASME Code — The American Society of Me- 
chanical Engineers' Boiler and Pressure Vessel 
Code published by that Society, including 
addenda and Code Cases, approved by the 
associated ASME Board. 

Assembler — An organization who purchases 
or receives from a manufacturer the necessary 
component parts of valves and assembles, 
adjusts, tests, seals, and ships safety or safety 
relief valves at a geographical location, and 
using facilities other than those used by the 
manufacturer. 

Authorized Inspection Agency — 

New Construction: An Authorized Inspection 
Agency is one that is accredited by the National 



Board meeting the qualification and duties of 
NB-360, Criteria for Acceptance of Authorized 
Inspection Agencies for New Construction. 

Inservice: An Authorized Inspection Agency 
is either: 

a) a jurisdictional authority as defined in 
the National Board Constitution; or 



b) an entity that is accredited by the Na- 
tional Board meeting NB 369, Quali- 
fications and Duties for Authorized 
Inspection Agencies Performing Inser- 
vice Inspection Activities and Quali- 
fications for Inspectors of Boilers and 
Pressure Vessels; NB-371 , Accreditation 
of Owner-User Inspection Organiza- 
tions (OUIO) or NB-390, For Federal 
Inspection Agencies (FIAs) Performing 
Inservice Inspection Activities. 

Capacity Certification — The verification by the 
National Board that a particular valve design or 
model has successfully completed all capacity 
testing as required by the ASME Code. 

Chimney or Stack — A device or means for 
providing the venting or escape of combustion 
gases from the operating unit. 

Confined Space — Work locations considered A09 
"confined" because their configurations hinder 
the activities of employees who must enter, 
work in and exit them. A confined space has 
limited or restricted means for entry or exit, 
and it is not designed for continuous employee 
occupancy. Confined spaces include, but are 
not limited to, underground vaults, tanks, stor- 
age bins, manholes, pits, silos, process vessels, 
and pipelines. Regulatory Organizations often 
use the term "permit-required confined space" 
(permit space) to describe a confined space that 
has one or more of the following characteris- 
tics: contains or has the potential to contain 
a hazardous atmosphere; contains a material 
that has the potential to engulf an entrant; has 
walls that converge inward or floors that slope 

24 



NATIONAL BOARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



downward and taper into a smaller area which 
could trap or asphyxiate an entrant; or contains 
any other recognized safety or health hazard, 
such as unguarded machinery, exposed live 
wires, or heat stress. Confined space entry 
requirements may differ in many locations and 
the Inspector is cautioned of the need to comply 
with local or site- specific confined space entry 
requirements. 

Conversion — 

Pressure Relief Devices: The change of a pres- 
sure relief valve from one capacity-certified 
configuration to another by use of manufac- 
turer's instructions. 

A07 Units of Measure: Changing the numeric value of 
a parameter from one system of units to another. 

Demonstration — A program of making evident 
by illustration, explanation, and completion of 
tasks documenting evaluation of an applicant's 
ability to perform code activities, including the 
adequacy of the appl icant's qual ity program, and 
by a review of the implementation of that program 
at the address of record and/or work location. 



Forced-Flow Steam Generator — A steam gen- 
erator with no fixed steamline and waterline. 

Inspection — A process of review to ensure 
engineering design, materials, assembly, ex- 
amination and testing requirements have been 
met and are compliant with the Code. 

Inspector — See National Board Commis- 
sioned Inspector and National Board Owner- 
User Commissioned Inspector. 

Intervening — Coming between or inserted 
between, as between the test vessel and the 
valve being tested. 

Jurisdiction — A governmental entity with the 
power, right, or authority to interpret and enforce 
law, rules, or ordinances pertaining to boilers, 
pressure vessels, or other pressure-retaining 
items. It includes National Board member juris- 
dictions defined as "jurisdictional authorities." 

Jurisdictional Authority — A member of the 
National Board, as defined in the National 
Board Constitution. 



Dutchman — Generally limited to tube or pipe 
cross-section replacement. The work necessary 
to remove a compromised section of material 
and replace the section with material meet- 
ing the service requirements and installation 
procedures acceptable to the Inspector. Also 
recognized as piecing. 

Examination — In process work denoting the 
act of performing or completing a task of inter- 
rogation of compliance. Visual observations, 
radiography, liquid penetrant, magnetic par- 
ticle, and ultrasonic methods are recognized 
examples of examination techniques. 

Exit — A doorway, hallway, or similar passage 
that will allow free, normally upright unencum- 
bered egress from an area. 

Field — A temporary location, under the control 
of the Certificate Holder, that is used for repairs 
and/or alterations to pressure-retaining items at 
an address different from that shown on the Cer- 
tificate Holder's Certificate of Authorization. 



Lift Assist Device — A device used to apply an 
auxiliary load to a pressure relief valve stem or 
spindle, used to determine the valve set pres- 
sure as an alternative to a full pressure test. 

Manufacturer's Documentation — The docu- 
mentation that includes technical information 
and certification required by the original code 
of construction. 

Mechanical Assembly — The work necessary to A08 
establish or restore a pressure retaining boundary, 
under supplementary materials, whereby pres- 
sure-retaining capability is established through a 
mechanical, chemical, or physical interface, as 
defined under the rules of the NBIC. 

Mechanical Repair Method — A method of 
repair, which restores a pressure retaining A08 
boundary to a safe and satisfactory operat- 
ing condition, where the pressure retaining 
boundary is established by a method other 
than welding or brazing, as defined under the 
rules of the NBIC 



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REPAIRS AND ALTERATIONS 



NBIC — The National Board Inspection Code 
published by The National Board of Boiler and 
Pressure Vessel Inspectors. 

"NR" Certificate Holder — An organization in 
possession of a valid "NR" Certificate of Autho- 
rization issued by the National Board. 

National Board — The National Board of Boiler 
and Pressure Vessel Inspectors. 

National Board Commissioned Inspector — An 

individual who holds a valid and current Na- 
tional Board Commission. 

Nuclear Items — Items constructed in accor- 
dance with recognized standards to be used in 
nuclear power plants or fuel processing facilities. 

Original Code of Construction — Documents 
promulgated by recognized national standards 
writing bodies that contain technical require- 
ments for construction of pressure-retaining items 
or equivalent to which the pressure-retaining item 
was certified by the original manufacturer. 

Owner or User — As referenced in lower case 
letters means any person, firm or corporation 
legally responsible for the safe operation of any 
pressure-retaining item. 

Owner-User Inspection Organization — An 

owner or user of pressure-retaining items that 
maintains an established inspection program, 
whose organization and inspection procedures 
meet the requirements of the National Board 
rules and are acceptable to the jurisdiction or 
jurisdictional authority wherein the owner or 
user is located. 

Owner-User Inspector — An individual who 
holds a valid and current National Board 
Owner-User Commission. 

Piecing — A repair method used to remove 
and replace a portion of piping or tubing ma- 
terial with a suitable material and installation 
procedure. 

Pressure-Retaining Items (PRI) — Any boiler, 
pressure vessel, piping, or material used for 



the containment of pressure, either internal or 
external. The pressure may be obtained from 
an external source, or by the application of 
heat from a direct source, or any combination 
thereof. 

Pressure Test — Prior to initial operation, the 
completed boiler, including pressure piping, 
water columns, superheaters, economizers, 
stop valves, etc., shall be pressure tested in a 
test performed in accordance with the original 
code of construction prior to initial operation 
of an installed unit that is witnessed by an 
Inspector. 

Repair — The work necessary to restore pres- 
sure-retaining items to a safe and satisfactory 
operating condition. 

Re-ending — A method used to join original 
code of construction piping or tubing with 
replacement piping or tubing material for the 
purpose of restoring a required dimension, 
configuration or pressure-retaining capacity. 

Re-rating — See alteration. 

"W Certificate Holder — An organization in 
possession of a valid "R" Certificate of Autho- 
rization issued by the National Board. 

Safety Relief Valves — A safety relief valve is 
a pressure relief valve characterized by rapid 
opening or pop action, or by opening in propor- 
tion to the increase in pressure over the opening 
pressure, depending on application. 

Settings — Those components and accessories 
required to provide support for the component 
during operation and during any related main- 
tenance activity. 

Shop — A permanent location, the address that 
is shown on the Certificate of Authorization, 
from which a Certificate Holder controls the 
repair and/or alteration of pressure-retaining 
items. 

Testing Laboratory — National Board accepted 
laboratory that performs functional and capac- 
ity tests of pressure relief devices. 



226 



NATIDNAL BDARD INSPECTION CODE • PART 3 — REPAIRS AND ALTERATIONS 



Transient — An occurrence that is maintained 
only for a short interval as opposed to a steady 
state condition. 

Velocity Distortion — The pressure decrease 
that occurs when fluid flows past the opening 
of a pressure sensing line. This is a distortion 
of the pressure that would be measured under 
the same conditions for a non or slowly mov- 
ing fluid. 

"VR" Certificate Holder — An organization in 
possession of a valid "VR" Certificate of Autho- 
rization issued by the National Board. 

Water Head — The pressure adjustment that 
must be taken into account due to the weight 
of test media (in this case, water) that is 0.433 
psi per vertical ft. (10 kPa per m.) added (sub- 
A07 tracted) from the gage pressure for each foot 
the gage is below (above) the point at which 
the pressure is to be measured. 



ZZ6. 1 



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226.2